Isuzu

2000
WORKSHOP MANUAL
TROOPER
RODEO
AMIGO
TROOPER(UX)
CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section.0
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A
Maintenance and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section.1
HVAC System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section.2
Power–Assisted Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A
Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C
Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D
Wheel and Tire System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E
DRIVELINE/AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section.4
Differential (Front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A1
Differential (Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2
Driveline Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B
Drive Shaft System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C
Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section.5
Brake Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A
Anti–lock Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B
Power-Assisted Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C
Parking Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section.6
Engine Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A
Engine Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B
Engine Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C
Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D1
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D2
Starting and Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3
Driveability and Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E
Engine Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F
Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G
Engine Speed Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6H
Inducton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6J
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section.7
Automatic Transmission (4L30–E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A
Transmission Control System (4L30–E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1
Manual Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C
Ligting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A
Wiper / Washer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B
Entertainment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C
Wiring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D
Meter and Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E
Body Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F
Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G
Security and Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H
Sunroof / Convertible Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I
Exterior / Interior Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J
RESTRAINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section.9
Seat Belt System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A
Supplemental Restraint System (SRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J
Restraint Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J1
CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section.10
Cruise Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A
GENERAL INFORMATION 0A–1
TROOPER
GENERAL INFORMATION
CONTENTS
General Information . . . . . . . . . . . . . . . . . . . . . 0A
Maintenance and Lubrication . . . . . . . . . . . . . 0B
GENERAL INFORMATION
CONTENTS
General Repair Instruction . . . . . . . . . . . . . . . . 0A–1 Lifting Instructions . . . . . . . . . . . . . . . . . . . . . . . 0A–10
Illustration Arrows . . . . . . . . . . . . . . . . . . . . . . . 0A–2 Standard Bolts Torque Specifications . . . . . . 0A–13
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A–3 Abbreviations Charts . . . . . . . . . . . . . . . . . . . . 0A–14
Theft Prevention Standard . . . . . . . . . . . . . . . . 0A–5 Service Parts Identification Plate . . . . . . . . . . 0A–15
General Repair Instruction 13. When removing or replacing parts that require
refrigerant to be discharged from the air conditioning
1. If a floor jack is used, the following precautions are system, be sure to use the Vehicle Refrigerant
recommended. Recovery and Recycling Equipment (VRRRE) to
Park vehicle on level ground, “block” front or rear recover and recycle Refrigerant–134a.
wheels, set jack against the recommended lifting 14. When a service operation is completed, make a final
points (see “Lifting Instructions” in this section), raise check to be sure the service has been done properly
vehicle and support with chassis stands and then and the problem has been corrected.
perform the service operations.
15. SUPPLEMENTAL RESTRAINT SYSTEM
2. Before performing service operations, disconnect The vehicle is equipped with a Supplemental
ground cable from the battery to reduce the chance of Restraint System. (SRS)—Air Bag.
cable damage and burning due to short circuiting.
This system is not to be serviced without consulting
3. Use a cover on body, seats and floor to protect them the appropriate service information.
against damage and contamination.
Consult Sections 9J1 and 9J “SRS System” if work is
4. Brake fluid and anti–freeze solution must be handled to be done on the front of the vehicle such as bumper,
with reasonable care, as they can cause paint sheet metal, seats, wiring, steering wheel or column.
damage.
Also review SRS system information if any arc
5. The use of proper tools and recommended essential welding is to be done on the vehicle.
and available tools, where specified, is important for
The SRS system equipped vehicle can be identified
efficient and reliable performance of service repairs.
by:
6. Use genuine Isuzu parts.
1. “AIR BAG” warning light on the instrument panel.
7. Used cotter pins, plastic clips, gaskets, O–rings, oil
seals, lock washers and self–locking nuts should be 2. A Code “J” or “K” for fifth digit of vehicle
discarded and new ones should be installed, as Identification Number.
normal function of the parts cannot be maintained if
these parts are reused.
8. To facilitate proper and smooth reassembly
operation, keep disassembled parts neatly in groups.
Keeping fixing bolts and nuts separate is very
important, as they vary in hardness and design
depending on position of installation.
9. Clean the parts before inspection or reassembly. Also
clean oil ports, etc. using compressed air, and make
certain they are free from restrictions.
10. Lubricate rotating and sliding faces of the parts with
oil or grease before installation.
11. When necessary, use a sealer on gaskets to prevent
leakage.
12. Carefully observe all specifications for bolt and nut
torques.
0A–2 GENERAL INFORMATION
Illustration Arrows
Arrows are designed for specific purposes to aid your understanding of technical illustrations.
Arrow Type Application Arrow Type Application
D Ambient/Clean air
Front of vehicle flow
D Cool air flow
D Gas other than

Up Side ambient air
D Hot air flow
D Ambient air mixed

with another gas
Task Related
D Can indicate
temperature change
View Detall Motion or direction
Lubrication point oil or

View Angle
fluid
Dimension (1:2) Lubrication point grease
Sectioning (1:3) Lubrication point jelly

Identification
Vehicle Identification Number (VIN)
This is the legal identification of the vehicle. it is located on
the left bottom of the windshield. It can be easily seen
through the windshield from outside the vehicle.
905RY00002
F00RY00002
Engine Serial Number Automatic : Stamped on the identification plate, located
The gasoline engine serial number is stamped on the left on the left side of the transmission above the mode
rear lower area of the cylinder block above the starter. switch.
240RW012
F06RW001
Transmission Serial Number

Manual : Stamped on the left side of the transmission
intermediate plate.
220RW084
Theft Prevention Standard

The 11 major components listed below will be marked
with 17 digit V.I.N. at the stage of production. In addition
its service parts will be marked with manufacturer’s trade
mark, “R” mark and “DOT” mark.
Reference INDICATION
COMPONENT
Figure No. PRODUCTION SERVICE PARTS
0A-10 ENGINE 1– 6VE1 V.I.N. plate
0A-11 TRANSMISSION 2– Manual transmission V.I.N. plate

– Automatic transmission
0A-11 BODY 3– Engine hood V.I.N. label

4– Front door
5– Rear door
6– Fender
7– Rear Quarter panel
8– Front bumper
9– Back door left side
10– Back door right side
11– Rear bumper
Anti Theft Stamping/Plate/Label

STAMPING/PLATE LABEL
PRODUCTION
SERVICE PARTS
Anti Theft Stamping/Label/Plate Location
The stamping, label and plate locations are indicated by
arrows in the illustration below.
NOTE:
A. VIN plate locations for production.
B. Stamping locations for service parts.
Engine
901RW195
Manual Transmission (AR–5)
901RX021
Automatic Transmission (THM)
901RW197
Body
901RW113
Legend (6) Fender

(3) Engine Hood (7) Rear Quarfer Panel
(4) Front Door (8) Front Bumper
(5) Rear Door
Body
901RW114
Legend (10) Back Door Right Side

(9) Back Door Left Side (11) Rear Bumper
Body Label Instructions
Do not peel off the masking tape until completion of paint
work when replacing these parts, as the tape is affixed on
the label attached to service parts for body of the
anti–theft component.
NOTE: Be sure to pull off the masking tape after paint
work has been completed.
Do not attempt to remove this label for any reason.
901RW083
Precautions in pulling off the masking tape

1. Use only your finger nail or a similar blunt instrument
to peel off the masking tape. Use of a sharp object will
damage the underlying anti–theft label.
2. Be careful not to damage the paint around the label.
901RY00057
Lifting Instructions
CAUTION:
D If a lifting device other than the original jack is used, it
is most important that the device be applied only to
the correct lifting points. Raising the vehicle from any
other point may result in serious damage.
D When jacking or lifting a vehicle at the frame side rail
or other prescribed lift points, be certain that lift pads
do not contact the catalytic converter, brake pipes or
cables, or fuel lines. Such contact may result in
damage or unsatisfactory vehicle performance.
Lifting Points and Supportable Point Locations
C00RW003
Lifting Point; Front Lifting Point; Rear
D When using a floor jack, lift on the center of the skid D Position the floor jack at the center of the rear axle
plate. case when lifting the vehicle.
545RS001 420RS002
Supportable Point; Front Supportable Point; Rear

D Position the chassis stands at the bottom of the frame D Position the chassis stands at the bottom of the frame
sidemember, behind the front wheel. sidemember, just behind the trailing link bracket.
501RS003 501RW002
Legend
(1) Trailing Link Bracket
Supportable Point; Rear
D Position the chassis stands at the bottom of the rear
axle case.
420RS001
Standard Bolts Torque Specifications

The torque values given in the following table should be
applied where a particular torque is not specified.
4.8 8.8 9.8
Strength Class
Refined Non-Refined
Bolt
Identification
Bolt Diameter ×
Pitch (mm)
M 6X1.0 4—8 (3—6) 5—10 N·m (4—7 lb ft) —
M 8X1.25 8—18 N·m (6—13 lb ft) 12—23 N·m (9—17 lb ft) 17—30 N·m (12—22 lb ft)
M 10X1.25 21—34 N·m (15—25 lb ft) 28—46 N·m (20—34 lb ft) 37—63 N·m (27—46 lb ft)
* M10X1.5 20—33 N·m (14—25 lb ft) 28—45 N·m (20—33 lb ft) 36—60 N·m (27—44 lb ft)
M12X1.25 49—74 N·m (36—54 lb ft) 61—91 N·m (45—67 lb ft) 76—114 N·m (56—84 lb ft)
The asterisk * indicates that the bolts are used for

female–threaded parts that are made of soft materials
such as casting, etc.
Abbreviations Charts Exh — Exhaust

° F — Degrees Fahrenheit
List of automotive abbreviations which may be used Fed — Federal (All States Except Calif.)
in this manual FF — Front Drive Front Engine
A — Ampere(s) FL — Fusible Link
ABS — Antilock Brake System FLW — Fusible Link Wire
AC — Alternating Current FP — Fuel Pump
A/C — Air Conditioning FRT — Front
ACCEL — Accelerator ft — Foot
ACC — Accessory FWD — Front Wheel Drive
ACL — Air Cleaner 4WD — Four Wheel Drive
Adj — Adjust 4 x 4 — Four Wheel Drive
A/F — Air Fuel Ratio 4 A/T — Four Speed Automatic Transmission/Transaxle
AIR — Secondary Air Injection System Gal — Gallon
Alt — Altitude GEN — Generator
AMP — Ampere(s) GND — Ground
ANT — Antenna Gov — Governor
ASM — Assembly g — Gram
A/T — Automatic Transmission/Transaxle Harn — Harness
ATDC — After Top Dead Center HC — Hydrocarbons
ATF — Automatic Transmission Fluid HD — Heavy Duty
Auth — Authority Hg — Hydrargyrum (Mercury)
Auto — Automatic HiAlt — High Altitude
BARO — Barometric Pressure HO2S — Heated Oxygen Sensor
Bat — Battery HVAC — Heater–Vent–Air–Conditioning
B+ — Battery Positive Voltage IAC — Idle Air Control
Bbl — Barrel IAT — Intake Air Temperature
BHP — Brake Horsepower IC — Integrated Circuit / Ignition Control
BPT — Backpressure Transducer ID — Identification / Inside Diameter
BTDC — Before Top Dead Center IGN — Ignition
° C — Degrees Celsius INJ — Injection
CAC — Charge Air Cooler IP — Instrument Panel
Calif — California IPC — Instrument Panel Cluster
cc — Cubic Centimeter Int — Intake
CID — Cubic Inch Displacement ISC — Idle Speed Control
CKP — Crankshaft Position J/B — Junction Block
CL — Closed Loop kg — Kilograms
CLCC — Closed Loop Carburetor Control km — Kilometers
CMP — Camshaft Position km/h — Kilometer per Hour
CO — Carbon Monoxide kPa — Kilopascals
Coax — Coaxial kV — Kilovolts (thousands of volts)
Conn — Connector kW — Kilowatts
Conv — Converter KS — Knock Sensor
Crank — Crankshaft L — Liter
Cu. In. — Cubic Inch lb ft — Foot Pounds
CV — Constant Velocity lb in — Inch Pounds
Cyl — Cylinder(s) LF — Left Front
DI — Distributor Ignition LH — Left Hand
Diff — Differential LR —Left Rear
Dist — Distributor LS — Left Side
DLC — Data Link Connector LWB — Long Wheel Base
DOHC — Double Overhead Camshaft L–4 — In–Line Four Cylinder Engine
DTC — Diagnostic Trouble Code MAF — Mass Air Flow
DTM — Diagnostic Test Mode MAN — Manual
DTT — Diagnostic Test Terminal MAP — Manifold Absolute Pressure
DVM — Digital Voltmeter (10 meg.) Max — Maximum
DVOM — Digital Volt Ohmmeter MC — Mixture Control
EBCM — Electronic Brake Control Module MFI — Multiport Fuel Injection
ECM — Engine Control Module MIL — Malfunction Indicator Lamp
ECT — Engine Coolant Temperature Min — Minimum
EEPROM — Electronically Erasable Programmable mm — Millimeter
Read Only Memory MPG — Miles Per Gallon
EGR — Exhaust Gas Recirculation MPH — Miles Per Hour
EI — Electronic Ignition M/T — Manual Transmission/Transaxle
ETR — Electronically Tuned Receiver MV — Millivolt
EVAP — Evaporation Emission
N — Newtons TVRS — Television & Radio Suppression
NA — Natural Aspirated TVV — Thermal Vacuum Valve
NC — Normally Closed TWC — Three Way Catalytic Converter
N·M — Newton Meters 3 A/T — Three Speed Automatic Transmission/Transaxle
NO — Normally Open 2WD — Two Wheel Drive
NOX — Nitrogen, Oxides of 4 x 2 — Two Wheel Drive
OBD — On-Board Diagnostic U–joint — Universal Joint
OD — Outside Diameter V — Volt(s)
O/D — Over Drive VAC — Vacuum
OHC — Overhead Camshaft VIN — Vehicle Identification Number
OL — Open Loop VRRRE — Vehicle Refrigerant Recovery and Recycling
O2 — Oxygen Equipment
O2S — Oxygen Sensor V–ref — ECM Reference Voltage
PAIR — Pulsed Secondary Air Injection System VSS — Vehicle Speed Sensor
P/B — Power Brakes VSV — Vacuum Switch Valve
PCM — Powertrain Control Module V–6 — Six Cylinder “V” Engine
PCV — Positive Crankcase Ventilation V–8 — Eight Cylinder ”V” Engine
PRESS — Pressure W — Watt(s)
PROM — Programmable Read Only Memory w/ — With
PNP — Park/Neutral Position w/b — Wheel Base
P/S — Power Steering w/o — Without
PSI — Pounds per Square Inch WOT — Wide Open Throttle
PSP — Power Steering Pressure
Pt. — Pint
Pri — Primary Service Parts Identification Plate
PWM — Pulse Width Modulate The Vehicle Information Plate (Service Parts ID plate) is
Qt. — Quart provided on all vehicle models.
REF — Reference It is located on the center dash wall inside the engine
RF — Right Front compartment. The plate lists the VIN (Vehicle
RFI — Radio Frequency Interference Identification Number), paint information and all
RH — Right Hand production options and special equipment on the vehicle
RPM — Revolutions Per Minute when it was shipped from the factory.
RPM Sensor — Engine Speed Sensor
RPO — Regular Production Option
RR — Right Rear
RS — Right Side
RTV — Room Temperature Vulcanizing
RWAL — Rear Wheel Antilock Brake
RWD — Rear Wheel Drive
SAE — Society of Automotive Engineers
Sec — Secondary
SFI — Sequential Multiport Fuel Injection
SI — System International
SIR — Supplemental Inflatable Restraint System
SOHC — Single Overhead Camshaft
Sol — Solenoid
SPEC — Specification
Speedo — Speedometer
SRS — Supplemental Restraint System
ST — Start / Scan Tool
Sw — Switch
SWB — Short Wheel Base
SYN — Synchronize 905RW007
Tach — Tachometer
TB — Throttle Body
TBI — Throttle Body Fuel Injection
TCC — Torque Converter Clutch
TCM — Transmission Control Module
TDC — Top Dead Center
Term — Terminal
TEMP — Temperature
TOD— Torque On Demand
TP — Throttle Position
TRANS — Transmission/Transaxle
TURBO — Turbocharger
MAINTENANCE AND LUBRICATION 0B–1
TROOPER
GENERAL INFORMATION
MAINTENANCE AND LUBRICATION
CONTENTS
Maintenance Schedule List . . . . . . . . . . . . . . . 0B–1 Lubricant Viscosity Chart . . . . . . . . . . . . . . . . . 0B–9
Explanation of Complete Vehicle Maintenance Recommended Liquid Gasket . . . . . . . . . . . 0B–11
Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B–5 Recommended Thread Locking Agents . . . 0B–12
Recommended Fluids and Lubricants . . . . 0B–8 Maintenance Service Data . . . . . . . . . . . . . . . . 0B–13
Maintenance Schedule List Severe Driving Conditions

If the vehicle is usually operated under any of the severe
Normal Vehicle Use driving conditions listed below, it is recommended that the
The maintenance instructions in this Maintenance applicable maintenance services be performed at the
Schedule are based on the assumption that the vehicle specified interval shown in the chart below.
will be used as designed:
Severe driving conditions:
D to carry passengers and cargo within the limitations
specified on the tire placard located on the inside of D Towing a trailer, using a camper or car top carrier.
the glove compartment door; D Repeated short trips of less than 8 km (5 miles) with
D to be driven on reasonable road surfaces within legal outside temperature remaining below freezing.
operating limits; D Extensive idling and/or low speed driving for long
D to be driven on a daily basis, as a general rule, for at distances, such as police, taxi or door-to-door
least several miles/kilometers; delivery use.
D to be driven on unleaded fuel D Operating on dusty, rough, muddy or salt spread
Unusual or severe operating conditions will require more roads.
frequent vehicle maintenance, as specified in the
following sections.
ITEMS INTERVAL
REPLACE TIMING BELT Every 75,000 miles (120,000 km)
CHANGE ENGINE OIL AND OIL FILTER Every 3,000 miles (4,800 km) or 3 months
CHANGE AUTOMATIC TRANSMISSION FLUID Every 20,000 miles (32,000 km)
CHANGE FRONT AND REAR AXLE OIL Every 15,000 miles (24,000 km)
CHANGE POWER STEERING FLUID Every 30,000 miles (48,000 km)
0B–2 MAINTENANCE AND LUBRICATION
Mileage Only Items

Mileage/Months
Explanation of Complete Vehicle Valve Clearance Adjustment

Maintenance Schedule Incorrect valve clearance will result in increased engine
noise and reduced engine output.
Brief explanations of the services listed in the preceding
Maintenance Scheduled are presented below. Retorque the camshaft bearing cap bolts before checking
Replace all questionable parts and note any necessary and adjusting the valve clearance.
repairs as you perform these maintenance procedures. Check and adjust the valve clearance if noise occurs.
Front and Rear Axle Lubricant Tire Rotation
Replacement Rotate tires every 7,500 miles (12,000 km).
Replace the front and rear axle lubricant at 15,000 miles
(24,000 km) and 30,000 miles (48,000 km) and after Front Wheel Bearings Lubricant
every 30,000 miles (48,000 km) or operation thereafter. Replacement
Clean and repack the front wheel bearings at 30,000
Manual Transmission Lubricant miles (48,000 km) intervals.
Replacement Refer to FRONT DRIVING AXLE (SEC. 4C).
Replace the transmission lubricant at 15,000 miles
(24,000 km) and 30,000 miles (48,000 km) and after Radiator Core and Air Conditioning
every 30,000 miles (48,000 km) of operation thereafter. Condenser Cleaning
Clean the front of the radiator core and air conditioning
Automatic Transmission Fluid condenser, at 60,000 miles (96,000 km) intervals.
Replacement
Check the fluid leakage at 15,000 miles (24,000 km) and Fluid Level Check
30,000 miles (48,000 km) and after every 15,000 miles A fluid loss in any system (except windshield
(24,000 km) or operation thereafter. washer) may indicate a problem. Repair the system
Replace the transmission fluid at 120,000 miles (192,000 at once.
km) of operation thereafter. Engine oil level
Transfer Case Lubricant Replacement Check level and add if necessary. The best time to check
the engine oil level is when the oil is warm. After stopping
Replace the transfer case lubricant at 15,000 miles the engine with the vehicle on a level surface, wait a few
(24,000 km) and 30,000 miles (48,000 km) and after minutes for the oil to drain back to the oil pan. Pull out the
every 30,000 miles (48,000 km) of operation thereafter. oil level indicator (dipstick). Wipe it clean and push the oil
level indicator back down all the way. Pull out the oil level
Extension Lubricant Level Check (2WD indicator, keeping the tip down, and look at the oil level on
only) it.
Check oil level at 15,000 miles (24,000 km) and 30,000 Add oil, if needed, to keep the oil level above the “ADD”
miles (48,000 km) and after every 30,000 miles (48,000 mark and between the “ADD” and “FULL” marks in the
km) or operation thereafter. operating range area. Avoid overfilling the engine since
this may cause engine damage. Push the oil level
Air Cleaner Element Replacement indicator back down all the way after taking the reading.
Replace the air cleaner under normal operating If you check the oil level when the oil is cold, do not run the
conditions every 30,000 miles (48,000 km). engine first. The cold oil will not drain back to the pan fast
Operation of the vehicle in dusty areas will necessitate enough to give a true oil level.
more frequent replacement. Engine coolant level and condition
Spark Plug Replacement Check engine coolant level in the coolant reservoir and
add engine coolant if necessary. Inspect the engine
Replace the plugs at 100,000 miles (160,000 km) coolant and replace it if dirty or rusty.
intervals with the type specified at the end of this section.
Windshield washer fluid level
Cooling System Service Check washer fluid level in the reservoir and add if
Drain, flush and refill system with new engine coolant. necessary.
Refer to “Recommended Fluids and Lubricants” in this Power steering system reservoir level
section, or ENGINE COOLING (SEC.6B). Check and keep at the proper level.
Timing Belt Replacement Brake master cylinder reservoir level
Replacement of the timing belt is recommended at every Check fluid. Keep fluid at proper level. A low fluid level can
100,000 miles (160,000 km). indicate worn disc brake pads which may need to be
Failure to replace the timing belt may result in serious serviced.
damage to the engine. Hydraulic clutch system
Check fluid level in the reservoir. Add fluid as required.
Battery fluid level normal highway speeds means a wheel balancing is
Check fluid level in the battery. needed. Check tire pressure when the tires are “cold”
(include the spare).
Fluid Leak Check Maintain pressure as shown in the tire placard, which is
located on the driver’s door lock pillar.
Check for fuel, water, oil or other fluid leaks by looking at
the surface beneath the vehicle after it has been parked Steering System Operation
for a while. Water dripping from the air conditioning
system after use is normal. If you notice gasoline fumes or Be alert for any changes in steering action. An inspection
fluid at any time, locate the source and correct it at once. or service is needed when the steering wheel is harder to
turn or has too much free play, or if there are unusual
Engine Oil and Oil Filter Replacement sounds when turning or parking.
Always use API SE, SF, SG, SH or ILSAC GF–1 quality Brake Systems Operation
oils of the proper viscosity.
When choosing an oil, consider the range of Watch for the “BRAKE” light coming on. Other signs of
temperatures the car will be operated in before the next oil possible brake trouble are such things as repeated pulling
change. Then, select the recommended oil viscosity from to one side when braking, unusual sounds when braking
the chart. or between brake applications, or increased brake pedal
Always change the oil and the oil filter as soon as possible travel. If you note one of these conditions, repair the
after driving in a dust storm. system at once.
For convenience, the following should be done when
Engine Cooling System Inspection wheels are removed for rotation: Inspect lines and hoses
for proper hookup, bindings, leaks, crack, chafing etc.
Inspect the coolant/anti–freeze. If the coolant is dirty or
Inspect disc brake pads for wear and rotors for surface
rusty, drain, flush and refill with new coolant. Keep coolant
condition.
at the proper mixture for proper freeze protection,
Inspect other brake parts, including parking brake drums,
corrosion inhibitor level and best engine operating
linings etc., at the same time. Check parking brake
temperature. Inspect hoses and replace if cracked,
adjustment.
swollen or deteriorated. Tighten the hose clamps if
Inspect the brakes more often if habit or conditions
equipped with screw–type clamps. Clean outside of
result in frequent braking.
radiator and air conditioning condenser. Wash filler cap
and neck. To help ensure proper operation, a pressure Parking Brake and Transmission Park
test of both the cooling system and the cap is also
Mechanism Operation
recommended.
Park on a fairly steep hill and hold the vehicle with the
Exhaust System Inspection parking brake only. This checks holding ability. On
Visually inspect the exhaust pipes, muffler, heat shields automatic transmission vehicles, shifting from “P”
and hangers for cracks, deterioration, or damage. position to the other positions cannot be made unless the
Be alert to any changes in the sound of the exhaust brake pedal is depressed when the key switch is in the
system or any smell of fumes. These are signs the system “ON” position or the engine is running.
may be leaking or overheating. Repair the system at WARNING: BEFORE CHECKING THE STARTER
once, if these conditions exist. (See also “Engine Exhaust SAFETY SWITCH OPERATION BELOW, BE SURE TO
Gas Safety” and “Three Way Catalytic Converter” in the HAVE ENOUGH ROOM AROUND THE VEHICLE.
Owner’s manual.) THEN FIRMLY APPLY BOTH THE PARKING BRAKE
AND THE REGULAR BRAKE. DO NOT USE THE
Fuel Cap, Fuel Lines, and Fuel Tank ACCELERATOR PEDAL. IF THE ENGINE STARTS,
Inspection BE READY TO TURN OFF THE KEY PROMPTLY.
TAKE THESE PRECAUTIONS BECAUSE THE
Inspect the fuel tank, the fuel cap and the fuel lines every VEHICLE COULD MOVE WITHOUT WARNING AND
60,000 miles (96,000 km) for damage which could cause POSSIBLY CAUSE PERSONAL INJURY OR
leakage. PROPERTY DAMAGE.
Inspect the fuel cap and the gasket for correct sealing and
physical damage. Replace any damaged parts.
Starter Safety Switch Operation
Drive Belt Inspection (Automatic Transmission)
Check the serpentine belt driving for cracks, fraying, Check by trying to start the engine in each gear while
wear, and correct tension every 30,000 miles (48,000 setting the parking brake and the foot brake. The starter
km). Replace as necessary. should crank only in “P” (Park) or “N” (Neutral).
Wheel Alignment, Balance and Tires Starter Safety Switch Operation (Manual
Operation Transmission)
Uneven or abnormal tire wear, or a pull right or left on a To check, place the shift lever in “Neutral”, push the clutch
straight and level road may show the need for a wheel pedal halfway and try to start. The starter should not
alignment. A vibration of the steering wheel or seat at
crank. The starter should crank only when the clutch
pedal is fully depressed.
Accelerator Linkage Lubrication

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

Inspect the front and rear suspension and steering
system for damaged, loose or missing parts or signs of
wear. Inspect power steering lines and hoses for proper
hookup, binding, leaks, cracks, chafing, etc.
Body and Chassis Lubrication

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

Except TOD model : yoke and universal joints with grease
containing MOS2 (disulfide molybdenum type grease) at
the interval shown in the Maintenance Schedule.
All models : check for play in normal direction of rotation of
sliding yoke and universal joints. Also check the propeller
shaft flange–to–pinion bolts for proper torque to 63 N•m
(46 lb ft) for front and rear propeller shaft.
Auto Cruise Control Inspection

Check to see if the clearance between cruise link and
accelerator link is normal. Also check that the connected
properly.
Clutch Lines and Hoses Inspection

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

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

Note the clutch pedal free play. It should be 5 – 15 mm (0.2
– 0.6 in). Adjust clutch control when there is little or no free
play.
Accelerator Linkage Inspection

Inspect for interference, binding, and damaged or
missing parts. Check accelerator pedal for smooth
operation and even pedal effort. Replace parts as
needed.
Recommended Fluids and Lubricants

USAGE FLUID/LUBRICANT
Engine API SE, SF, SG, SH or ILSAC GF-1 Engine oil (See oil
chart on the following page for proper viscosity)
Mixture of water and good quality ethylene glycol base
Engine coolant
type antifreeze.
Brake system DOT-3 hydraulic brake fluid.
Power steering system DEXRON -III Automatic transmission fluid.
Automatic transmission DEXRON -III Automatic transmission fluid.
Manual transmission Engine oil
(See oil chart on following page for proper viscosity)
Rear axle and front axle GL-5 gear lubricant (Standard differential)
GL-5 Limited slip differential gear lubricant together with
limited slip differential lubricant additive (Part No.
8-01052-358-0) or equivalent (If equipped with optional
limited slip diferential) (See oil chart in this section for
proper viscosity)
Clutch system
a. Pivot points Engine oil
b. Clutch fork joint Chassis grease
c. Master cylinder DOT-3 hydraulic brake fluid
Hood latch assembly
a. Pivots and spring anchor Engine oil
b. Release pawl Chassis grease
Hood and door hinges Engine oil
Chassis lubrication Chassis grease
Parking brake cables Chassis grease
Front wheel bearings Wheel bearing grease
Shift on the fly system GL-5 gear lubricant
Transfer Case (Except TOD and 2WD model) SAE40 (Areas where ambient temperatures of 32°C
(90°F) and higher are regularly encountered.)
SAE5W–30SF (Other areas)
TOD system DEXRON -III Automatic transmission fluid.
Extension assembly DEXRON -III Automatic transmission fluid.
Propeller shafts (Except TOD model) Grease containing MoS2 or multipurpose type grease
NLGI No.2
Sliding yoke and Univeral joint
Body door hinge pins and linkage, fuel door hinge, rear Engine oil
compartment lid hinges
Windshield washer solvent Washer fluid
Key lock cylinder Synthetic light weight engine oil (SAE 5W-30)
Accelerator linkage Chassis grease
Lubricant Viscosity Chart

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

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

Agents
LOCTITE Type LOCTITE Color
LOCTITE 242 Blue
LOCTITE 262 Red
LOCTITE 271 Red
Application Steps
1. Completely remove all lubricant and moisture from
the bolts and the female-threaded surfaces of the
parts to be joined.
The surfaces must be perfectly dry.
2. Apply LOCTITE to the bolts.
F00RW014
3. Tighten the bolts to the specified torque.

After tightening, be sure to keep the bolts free from
vibration and torque for at least an hour until
LOCTITE hardens.
NOTE: When the application procedures are specified in
this manual, follow them.
Maintenance Service Data

Service Data and Specifications
ENGINE Valve clearance (cold) Intake 0.28±0.05 mm (0.011 in)
Exhaust 0.3±0.05 mm (0.015 in)
Spark plug type K16PR-P11/PK16PR11/RC10PYP4
Spark plug gap 1.05 mm (0.04 in)
CLUTCH Clutch pedal free play 5-15 mm (0.197-0.591 in)
BRAKE Brake pedal free play 6-10 mm (0.24-0.39 in)
Parking brake travel 6-7 notches
WHEEL ALIGNMENT Toe-in 0±2 mm (0±0.08 in)
Camber 0°±30’
Caster 2° 10’±45’
PROPELLER SHAFT Flange torque 63 N•m (46 lb ft) (Except TOD model)
43 N•m (32 lb ft) (TOD model)
WHEEL AND TIRES Wheel nut torque 118 N•m (87 lb ft)
Tire inflation pressure (Front) 210 kPa (30 psi)
* Tire inflation pressure (Rear) 240 kPa (35 psi)
* Unless otherwise specified on tire information label on the vehicle.
Approximate Capacities
Items Metric Measure U.S. Measure
Fuel tank 85 L 22.5 Gal.
* Crankcase Oil Change with Filter 4.7 L 5.0 Qt
Oil Change without Filter 4.0 L 4.3 Qt
Coolant M/T 8.5 L 9.0 Qt
A/T 8.8 L 9.3 Qt
Transmission Manual 2.7 L 2.86 Qt
Automatic 8.6 L 9.1 Qt
Transfer 1.45 L 1.5 Qt
Transfer with TOD 1.9 L 2.0 Qt
Extention 0.185 L 0.195 Qt
Axle Rear 3.0 L 3.2 Qt
Front (4WD vehicle only) 1.4 L 1.5 Qt
Shift on the fly system 0.12 L 0.13 Qt
Power steering 1.0 L 1.1 Qt
Air conditioning (R-134a) 0.6 Kg 1.32 Ibs
*Crankcase capacities shown are approximate refill capacities. After refill, recheck oil level.
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 1A–1
TROOPER
HEATING, VENTILATION AND AIR

CONDITIONING (HVAC)
HVAC SYSTEMS
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 1A–3 Center Vent, Drive Side Vent and
Heating and Ventilation System . . . . . . . . . . . 1A–3 Associated Parts . . . . . . . . . . . . . . . . . . . . . . 1A–25
General Description . . . . . . . . . . . . . . . . . . . . . 1A–3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–25
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 1A–8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–25
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–9 Control Lever Assembly and / or Control
Individual Inspection . . . . . . . . . . . . . . . . . . . . . 1A–12 Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–26
Heater Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–14 Control Lever Assembly, Control Cable
and Associated Parts . . . . . . . . . . . . . . . . . . 1A–26
Heater Unit and Associated Parts . . . . . . . . 1A–14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–15
Control Panel Illumination Bulb . . . . . . . . . . . . 1A–28
Heater Core and / or Mode Door . . . . . . . . . . 1A–16
Control Panel Illumination Bulb and
Disassembled View . . . . . . . . . . . . . . . . . . . . 1A–16
Associated Parts . . . . . . . . . . . . . . . . . . . . . . 1A–28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–28
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–17
Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–29
Heater Mode Control Link Unit . . . . . . . . . . . . 1A–18
Resistor and Associated Parts . . . . . . . . . . 1A–29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–19
Air Conditioning System . . . . . . . . . . . . . . . . . . 1A–30
Heater Temperature Control Link Unit . . . . . . 1A–19
General Description . . . . . . . . . . . . . . . . . . . . . 1A–30
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–39
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–19
Individual Inspection . . . . . . . . . . . . . . . . . . . . . 1A–47
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–19
General Repair Procedure . . . . . . . . . . . . . . 1A–48
Blower Assembly . . . . . . . . . . . . . . . . . . . . . . . . 1A–20
Compressor Assembly . . . . . . . . . . . . . . . . . . . 1A–55
Blower Assembly and Associated Parts . . 1A–20
Compressor Assembly and Associated
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–20 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–55
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–21 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–55
Blower Link Unit and / or Mode door . . . . . . . 1A–21 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–56
Disassembled View . . . . . . . . . . . . . . . . . . . . 1A–21 Condenser Assembly . . . . . . . . . . . . . . . . . . . . 1A–57
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–21 Condenser Assembly and Associated Parts 1A–57
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–23 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–57
Blower Motor and Associated Parts . . . . . . 1A–23 Receiver / Drier . . . . . . . . . . . . . . . . . . . . . . . . . 1A–58
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–23 Receiver / Drier and Associated Parts . . . . 1A–58
Rear Heater Duct, Defroster Nozzle and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–58
Ventilation Duct . . . . . . . . . . . . . . . . . . . . . . . . . 1A–24
Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . 1A–59
Rear Heater Duct, Defroster Nozzle,
Pressure Switch and Associated Parts . . . 1A–59
Ventilation Duct and Associated Parts . . . 1A–24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–59
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–59
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–25
Evaporator Assembly . . . . . . . . . . . . . . . . . . . . 1A–60
Center and / or Drive Side Vent . . . . . . . . . . . 1A–25
Evaporator Assembly and Associated Parts 1A–60
1A–2 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–60 Full Automatic Air Conditioner Parts
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–61 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . 1A–81
Electronic Thermostat, Evaporator Core Refrigerant Line and Associated Parts . . . . 1A–82
and/or Expansion Valve . . . . . . . . . . . . . . . . . 1A–61 Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 1A–83
Disassembled View . . . . . . . . . . . . . . . . . . . . 1A–61 Functions and Features . . . . . . . . . . . . . . . . . . 1A–88
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–61 Automatic Air Conditioner Block Diagram . . . 1A–89
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–62 Control Panel Layout . . . . . . . . . . . . . . . . . . . . 1A–90
Air Conditioning Switch and Illumination Bulb 1A–63 Air Control Functions . . . . . . . . . . . . . . . . . . . . 1A–91
Air Conditioning Switch, Illumination Bulb Operation and Functions of Control Panel
and Associated Parts . . . . . . . . . . . . . . . . . . 1A–63 Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–92
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–63 Overview of Construction, Movement and
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–63 Control of Major Parts of Automatic Air
Conditioner System . . . . . . . . . . . . . . . . . . . . . 1A–94
Refrigerant Line . . . . . . . . . . . . . . . . . . . . . . . . . 1A–64
Overview of Automatic Control of Automatic
Refrigerant Line and Associated Parts . . . . 1A–64 Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . 1A–98
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–64
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 1A–102
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–65
Troubleshooting, Its Overview and
Main Data And Specifications . . . . . . . . . . . . . 1A–66 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–102
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–68 Auto Air Conditioner Control Unit Power
Service Precaution . . . . . . . . . . . . . . . . . . . . 1A–68 Supply Diagnosis . . . . . . . . . . . . . . . . . . . . . 1A–103
General Description . . . . . . . . . . . . . . . . . . . . . 1A–68 Performance and Movement checklist for
Metric Thread Size Information . . . . . . . . . . . . 1A–70 Automatic Air Conditioner Related Parts . 1A–105
Compressor Clutch Plate and Hub Assembly 1A–70 Troubleshooting With Self-Diagnosis
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–70 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–107
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–70 Inspection By Failed Location . . . . . . . . . . . . . 1A–111
Compressor Clutch Rotor and/or Bearing . . . 1A–71 Inspection of the Sensors . . . . . . . . . . . . . . . 1A–111
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–71 Inspection of the Intake Actuator System . 1A–115
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–71 Inspection of the Mix Actuator System . . . . 1A–118
Compressor Clutch Coil . . . . . . . . . . . . . . . . . . 1A–72 Inspection of the Mode Actuator System . . 1A–121
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–72 Inspection of the Fan Motor System . . . . . . 1A–124
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–73 Inspection of the Magnetic Clutch System 1A–129
Individual Inspection . . . . . . . . . . . . . . . . . . . 1A–132
Compressor Shaft Seal . . . . . . . . . . . . . . . . . . 1A–74
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 1A–74 On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . 1A–135
Seal Leak Detection . . . . . . . . . . . . . . . . . . . 1A–74 Power Transistor . . . . . . . . . . . . . . . . . . . . . . 1A–135
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–74 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–135
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–75 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–135
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–75 Automatic Heater/Air Conditioner Control
Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–135
Compressor Pressure Relief Valve . . . . . . . . 1A–76
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–135
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–76
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–135
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–76
In Car Sensor . . . . . . . . . . . . . . . . . . . . . . . . . 1A–136
Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . 1A–76
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–136
Compressor Oil Check . . . . . . . . . . . . . . . . . 1A–76
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–136
Checking and Adjusting Oil Quantity for
Ambient Sensor . . . . . . . . . . . . . . . . . . . . . . . 1A–136
Used Compressor . . . . . . . . . . . . . . . . . . . . . 1A–76
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–136
Checking and Adjusting for Compressor
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–136
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 1A–76
Sun Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–137
Contamination of Compressor Oil . . . . . . . . 1A–77
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–137
Oil Return Operation . . . . . . . . . . . . . . . . . . . 1A–77
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–137
Replacement of Component Parts . . . . . . . 1A–77
Electronic Thermostat . . . . . . . . . . . . . . . . . . 1A–137
Compressor Leak Testing (External and
Internal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–77 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–137
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–79 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–137
Mode Actuator . . . . . . . . . . . . . . . . . . . . . . . . 1A–138
Automatic Air Conditioning System . . . . . . . . 1A–81
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–138
General Description . . . . . . . . . . . . . . . . . . . . . 1A–81
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–138 Intake Actuator . . . . . . . . . . . . . . . . . . . . . . . . 1A–139
Mix Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–138 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–139
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–138 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–139
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–138
Service Precaution CAUTION: Always use the correct fastener in the

proper location. When you replace a fastener, use
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL ONLY the exact part number for that application.
RESTRAINT SYSTEM (SRS). REFER TO THE SRS ISUZU will call out those fasteners that require a
COMPONENT AND WIRING LOCATION VIEW IN replacement after removal. ISUZU will also call out
ORDER TO DETERMINE WHETHER YOU ARE the fasteners that require thread lockers or thread
PERFORMING SERVICE ON OR NEAR THE SRS sealant. UNLESS OTHERWISE SPECIFIED, do not
COMPONENTS OR THE SRS WIRING. WHEN YOU use supplemental coatings (Paints, greases, or other
ARE PERFORMING SERVICE ON OR NEAR THE SRS corrosion inhibitors) on threaded fasteners or
COMPONENTS OR THE SRS WIRING, REFER TO fastener joint interfaces. Generally, such coatings
THE SRS SERVICE INFORMATION. FAILURE TO adversely affect the fastener torque and the joint
FOLLOW WARNINGS COULD RESULT IN POSSIBLE clamping force, and may damage the fastener. When
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR you install fasteners, use the correct tightening
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. sequence and specifications. Following these
instructions can help you avoid damage to parts and
systems.
Heating and Ventilation System
General Description
Heater
When the engine is warming up, the warmed engine
coolant is sent out into the heater core. The heater system
supplies warm air into the passenger compartment to
warm it up.
Outside air is circulated through the heater core of the
heater unit and then back into the passenger
compartment. By controlling the mixture of outside air and
heater core air, the most comfortable passenger
compartment temperature can be selected and
maintained.
The temperature of warm air sent to the passenger
compartment is controlled by the temperature control
knob. This knob acts to open and close the air mix door,
thus controlling the amount of air passed through the
heater core.
The air selector knob, with its different modes, also allows
you to select and maintain the most comfortable
passenger compartment temperature.
The air source select lever is used to select either
“FRESH” for the introduction of the outside air, or
“RECIRC” for the circulation of the inside air. When the
lever is set to “FRESH”, the outside air is always taken
into the passenger compartment. When setting the lever
to “RECIRC” position, the circulation of air is restricted
only to the inside air with no introduction of the outside air
and the air in the passenger compartment gets warm
quickly. However, the lever is normally set to “FRESH” to
prevent the windshield from clouding.
840RS004
Legend (8) Duct

(1) Side Defroster Hose (9) Heater Unit
(2) Vent Box (10) Rear Heater Duct
(3) Upper Center Vent Box (11) Lap Vent Nozzle
(4) Lower Center Vent Box (12) Vent Box
(5) Blower Assembly (13) Side Defroster Hose
(6) Control Lever Assembly (14) Defroster Nozzle
(7) Evaporator Assembly
Control Lever Assembly
The vehicle has cable-type-control to control the mode The fan control is used to control the amount of air sent
and temperature of the heater unit and the mode door for out by the resistor at four levels from “LOW” to “HIGH”.
the air source of the blower assembly.
865RW007
Legend (3) Fan Control Knob (Fan Switch)

(1) Air Source Select Lever (4) Air Conditioning (A/C) Switch (W/ A/C)
(2) Air Select Knob (5) Temperature Control Knob
Ventilation
Set “AIR SOURCE SELECT LEVER” to “FRESH” The blower fan also serves to deliver fresh outside air to
position and turn on the blower fan. Heating can be done the vehicle interior to assure adequate ventilation.
in this lever position, sending in fresh air from outside.
C01RS001
Air Select Knob
The air select knob allows you to direct heated air into the Selecting this mode allows air conditioning system to
passenger compartment through different outlets. work when the fan switch is turned to on position,
1. Vent – In this position, air is discharged from the even if the A/C switch is off.
upper air outlet. Air quantity is controlled by the fan 5. Defrost – In this position, most of the air is delivered
control knob. to the windshield and a small amount is delivered to
2. Bi-Level – In this position, air flow is divided between the side windows.
the upper air outlets and the floor air outlets, with Moving the air source select lever to the “CIRC” position
warmer air delivered to the floor outlets than the air provides quickest heat delivery by closing the blower
delivered to the upper air outlets. assembly mode door. In this position, outside air is not
3. Foot – In this position, air flow is delivered to the foot delivered to the passenger compartment.
while sending approx 30% op total amount air to the Selecting this mode allows air conditioning system to
wind shield. work when the fan switch is turned to on position, even if
4. Def/Foot – In this position, air flow is delivered to the the A/C switch is off.
foot, while sending approx. 40% of total amount of air
to the windshield.
C01RW001
Air Source Select Lever Temperature Control Knob

The intake of outside air and the circulation of inside air When the temperature control knob is in the “COLD”
are controlled by sliding this lever left or right. position, the air mix door closes to block the air flow to the
heater core.
Fan Control Knob When the temperature control knob is in the “HOT”
This knob controls the blower motor speed to regulate the position, the air mix door opens to allow air to pass
amount of air delivered to the defrost, foot, and ventilation through the heater core and heat the passenger
ducts: compartment
1. Low Placing the knob in a intermediate position will cause a
lesser or greater amount air to reach the heater core. In
2. Medium Low
this mode the passenger compartment temperature can
3. Medium High be regulated
4. High
Wiring Diagram
D01RS005
Diagnosis
Heating Cycle diagnosis
Condition Possible cause Correction
No heating or insufficient heating. Blower motor does not run or runs Refer to “FAN CONTROL LEVER
improperly. (FAN SWITCH) DIAGNOSIS”.
Engine coolant temperature is low. Check the engine coolant
temperature after warming up the
engine and check the thermostat.
Replace as necessary.
Insufficient engine coolant. Add engine coolant as required.
Circulation volume of engine coolant Check if the water hose to the heater
is insufficient. core is clogged, collapsed or twisted.
Repair or replace as necessary.
Heater core clogged or collapsed. Clean or replace as necessary.
The heater cores is not provided with Repair the temperature control link
air sent from the blower motor. unit or mode doors.
Duct connections defective or Repair or replace as necessary.
unsealing.
Control lever moves but mode door Cable attaching clip is not correct. Repair
does not operate.
operate
Link unit of heater or blower Repair
assembly defective.
The mode door cannot be set to the Link unit of heater unit or blower Repair.
mode selected. assembly defective.
Control cable is not adjusted. Adjust.
Fan Control Lever (Fan Switch) Diagnosis
Current flows to the blower motor through the heater and For the inspection of the relays, switches and units in
the A/C relay (B-36) to activate the rotation of the blower each table, refer to “INDIVIDUAL INSPECTION” in this
motor by turning “ON” the fan control knob (fan switch). section.
Blower motor speed is controlled in stages by the resistor,
by operating the switch from “LOW” to “HIGH”.
D01RS004

Blower motor does not run. — Refer to Chart A
Blower motor does not run in certain — Refer to Chart B, C, D and E
position (s).
Blower motor does not stop at “OFF” — Refer to Chart F
position.
Chart “A” Blower Motor Dose Not Run

Step Action Yes No
1 Is relay (B-36) OK? Go to Step 2 Replace
2 Is fuse C-19 (25A) OK? Go to Step 3 Replace
3 Is resistor OK? Go to Step 4 Replace
4 Is fan control knob OK? Replace control
Go to Step 5 lever assembly.
5 Is blower motor OK? Go to Step 6 Replace
6 1. Turn the ignition switch “ON”. Poor ground or
2. Turn fan control knob “ON”. open circuit either
3. Check to see if battery voltage is present at chassis side between chassis
connector terminal No. B5-1 side connector
terminal No. B5-2
Is there a battery voltage?
and No. B3-2 or Open circuit
No. I18-1 and between No.
body ground (No. C-19 (25A) fuse
B-2). and No. B5-1.
Chart “B” Blower Motor Does Not Run At Low Position

Step Action Yes No
2 Is fan control knob (Fan Switch) OK? Open circuit
between chassis
side connector
terminal No. B3-1 Replace control
and No.I18-2. lever assembly.
Chart “C” Blower Motor Dose Not Run At Medium Low Position
Step Action Yes No
between the
chassis side
connector
and No. I18-5. lever assembly.
Chart “D” Blower Motor Dose Not Run At Medium High Position
Step Action Yes No
between chassis
side connector
Chart “E” Blower Motor Dose Not Run At High Position

Step Action Yes No
between Chassis
side connector
Chart “F” Blower Motor Does Not Stop In The “OFF” Position
Step Action Yes No
1 Is the fan control knob (Fan Switch) OK? Short circuit
between chassis
side connector
terminal No. B5-2
and
No. B3-2,No. B3-
3 and No. I18-6,
No. B3-6 and
No. I18-3,
No. B3-4 and
No. I18-5 or
No. B3-1 and Replace control
No. I18-2 lever assembly.
Individual Inspection Resistor

Blower Motor 1. Disconnect the resistor (B-3) connector.
2. Check for continuity and resistance between the
1. Disconnect the blower motor (B-5) connector from terminals of the resistor.
the blower motor.
2. Connect the battery positive terminal to the No. 1
terminal of the blower motor and the negative to the
No. 2.
3. Be sure to check to see if the blower motor operates
correctly.
840RS001
873RS005
Fan switch Resistor terminals

Resistance
position with continuity
1 1—2 2.4 W
2 2—4 0.90 W
3 2—6 0.28 W
4 2—3 —
Fan Control Knob (Fan Switch)

1. Check for continuity between the terminals of the fan
switch.
825RS001
2. Check for continuity between the heater and the A/C

relay (B-36) terminals.
865RS001
Fan switch Switch connector terminals with con-

position tinuity
OFF No continuity
1 1–2–4
2 1–4–5
3 1–3–4 825RS002
4 1–4–6 Relay terminals with

Condition
continuity
Heater & A/C Relay Normal 1 – 3 (Approx 85–105W)

When battery voltage is
1. Disconnect the heater and the A/C relay (B-36). 2–4
applied between 1 – 3
D When removing the connector for relay, unfasten
the tang lock of the connector by using a
screwdriver, then pull the relay (1) out.
Heater Unit
Heater Unit and Associated Parts
860RY00005
Legend (7) Heater Unit Assembly

(1) Instrument Panel Assembly (8) Center Ventilation Lower Duct
(2) Instrument Panel Center Bracket (9) Driver Lap Vent Nozzle
(3) Resistor (10) Water Hose
(4) Duct (11) Electro Thermo Connector (With A/C)
(5) Evaporator Assembly (A/C only) (12) Resistor Connector
(6) Rear Heater Duct
Removal 4. Remove the Instrument panel assembly.

D Refer to Instrument Panel Assembly in Body and
1. Disconnect the battery ground cable. Accessories section.
2. Drain the engine coolant. 5. Disconnect the water hoses at the heater unit.
3. Discharge and recover refrigerant (with air 6. Disconnect resistor connector.
conditioning)
7. Remove duct.
D Refer to Refrigerant Recovery in this section.
8. Remove evaporator assembly (A/C only).
D Refer to Evaporator Assembly in this section.
9. Remove instrument panel center bracket.
D Refer to Cross Beam Assembly in Body and
Accessories section.
10. Remove rear heater duct.
11. Remove heater unit assembly.
12. Remove driver lap vent nozzle.
13. Remove center ventilation lower duct.
Installation
To install, follow the removal steps in the reverse order,
noting the following points:
1. When handling the PCM and the control unit, be
careful not to make any improper connection of the
connectors.
2. Adjust the control lever assembly cables.
D Refer to Control Lever Assembly in this section.
3. When installing the heater unit, defroster nozzle and
center vent duct, be sure that the proper seal is made,
without any gap between them.
Heater Core and / or Mode Door

Disassembled View
860RS001
Legend (4) Heater Unit

(1) Case (Temperature Control) (5) Case (Mode Control)
(2) Mode Door (6) Heater Core
(3) Duct
Removal 4. Remove heater unit.

D Refer to Heater Unit in this section.
1. Disconnect the battery ground cable.
5. Remove duct.
2. Drain the engine coolant.
6. Remove case (Mode control) and do not remove link
3. Discharge and recover refrigerant (with air unit at this step.
conditioning).
7. Remove case (Temperature control). Separate two 9. Pull out the mode door while raising up the catch of
halves of core case. the door lever.
860RS002 860RS004
8. Remove heater core (1).

Inspection
Check for foreign matter in the heater core, stains or core
fin damage.
Installation
noting the following point:
1. Check that each mode door operates properly.
860RS003
Heater Mode Control Link Unit

Disassembled View
860RS005
Legend (4) Clip

(1) Case (Mode Control) (5) Door Lever
(2) Heater Unit (6) Rod
(3) Mode Sub-lever (7) Washer and Mode Main Lever
Removal
2. Drain engine coolant.
3. Discharge and recover refrigerant (with air
conditioning).
4. Remove heater unit.
5. Remove the case (Mode control) from heater unit.
6. Remove washer and the mode main lever.
7. Remove rod.
8. Press the tab of the sub-lever inward, and take out the
sub-lever.
9. Pull out the door lever while raising up the catch of the
door lever.
860RS006
10. Remove clip.

Installation 2. After installing the link unit, check to see if the link unit
operates correctly.
To install, follow the remove steps in the reverse order,
1. Apply grease to the mode sub-lever and to the
abrasive surface of the heater unit.
Heater Temperature Control Link Unit

Disassembled View
860RS007
Legend (4) Clip

(1) Case (Temperature control) (5) Heater Unit
(2) Clip (6) Rod
(3) Door Lever (7) Sub-lever
Removal 8. Pull out the door lever while raising up the catch of the
door lever.
1. Disconnect the battery ground cable. 9. Remove clip.
conditioning). Installation
D Refer to Refrigerant Recovery in this section. To install, follow the removal steps in the reverse order,
1. Apply grease to the sub-lever and to the abrasive
D Refer to Heater Unit in this section. surface of the heater unit.
5. Remove the case (Temperature control) from the 2. After installing the link unit, check to see if the link unit
heater unit. operates correctly.
6. Remove rod.
7. Remove sub-lever.
Blower Assembly
Blower Assembly and Associated Parts
873RY00003
Legend (5) Blower Assembly

(1) Electro Thermo Connector (6) Duct
(2) Blower Motor Connector (7) Evaporator Assembly (A/C only)
(3) Resistor Connector (8) Heater Unit
(4) Dash Side Trim Panel (RH) (9) Instrument Panel Assembly
Removal 4. Disconnect resistor connector.

5. Remove duct.
conditioning). D Refer to Evaporator Assembly in this section.
D Refer to Refrigerant Recovery in this section. 7. Remove dash side trim panel (RH).
3. Remove instrument panel assembly. 8. Disconnect blower motor connector.
D Refer to Instrument Panel Assembly in Body and 9. Remove blower assembly.
Installation
1. Adjust the control lever assembly cables.
Blower Link Unit and / or Mode door

Disassembled View
873RS001
Legend (4) Sub Lever

(1) Upper Case (5) Door Lever
(2) Mode Door (6) Blower Assembly
(3) Lower Case
Removal 2. Discharge and recover refrigerant (with air

conditioning).
1. Disconnect the battery ground cable. D Refer to Refrigerant Recovery in this section.
3. Remove blower assembly.
D Refer to Blower Assembly in this section.
4. Remove lower case.
5. Separate the upper case and slit the lining parting
face with a knife.
873RS002
6. Pull out the mode door while lifting up the catch of

door lever.
8. Remove door lever.
Installation
1. Apply grease to the door lever and to the abrasive
surface of the upper case.
2. Apply an adhesive to the parting face of the lining
when assembling the upper case.
Blower Motor
Blower Motor and Associated Parts
873RS004
Legend (4) Fan

(1) Blower Motor Connector (5) Blower Motor
(2) Blower Motor Assembly (6) Attaching Screw
(3) Clip
Removal Installation
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order.
2. Remove blower motor connector.
3. Remove attaching screw.
4. Remove blower motor assembly.
5. Remove clip.
6. Remove fan.
7. Remove blower motor.
Rear Heater Duct, Defroster Nozzle and Ventilation Duct

Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts
874RS017
Legend (6) Center Console

(1) Center Defroster Nozzle (7) Rear Heater Duct
(2) Side Defroster Nozzle (8) Driver Lap Duct
(3) Side Ventilation Duct (9) Cross Beam Assembly
(4) Center Ventilation Upper Duct (10) Instrument Panel Assembly
(5) Center Ventilation Lower Duct
Removal 6. Remove driver lap duct.

7. Remove center console.
2. Remove instrument panel assembly.
D Refer to Consoles in Body and Accessories
D Refer to Instrument Panel Assembly in Body and section.
9. Remove cross beam assembly.
3. Remove center ventilation upper duct.
4. Remove side ventilation duct. Accessories section.
5. Remove center ventilation lower duct.
10. Remove side defroster nozzle.
11. Remove center defroster nozzle.
Installation
1. Connect each duct and nozzle securely leaving no
clearance between them and making no improper
matching.
Center and / or Drive Side Vent

Center Vent, Drive Side Vent and Associated Parts
740RS003
Legend (4) Front Console Assembly

(1) Center Vent (5) Instrument Panel Driver Lower Cover
(2) Meter Cluster Assembly Assembly
(3) Lower Cluster Assembly (6) Side Vent
Removal 6. Remove screws and the center vent from center

cluster while prying up the center vent catch portions.
1. Disconnect the battery ground cable. 7. Remove screws and the side vent from the center
2. Remove front console assembly. cluster while prying up the vent catch portions.
3. Remove lower cluster assembly.
4. Remove instrument panel driver lower cover Installation
assembly.
To install, follow the removal steps in the reverse order.
5. Remove meter cluster assembly.
Control Lever Assembly and / or Control Cable

Control Lever Assembly, Control Cable and Associated Parts
865RS011
Legend (7) Attaching Screws

(1) Instrument Panel Passenger Lower Cover (8) Control Lever Assembly
Assembly (9) Mode Control Link Connection
(2) Glove Box (10) Front Console Assembly
(3) Fan Switch and Air Conditioning Switch (11) Lower Cluster Assembly
Connector (12) Instrument Panel Driver Lower Cover
(4) Temp Control Link Connection Assembly
(5) Control Cable (13) Meter Cluster Assembly
(6) Blower Assembly Connection
Removal 5. Remove instrument panel passenger lower cover

assembly.
1. Disconnect the battery ground cable. 6. Remove instrument panel driver lower cover
2. Remove front console assembly. assembly.
3. Remove lower cluster assembly. 7. Remove meter cluster assembly.
4. Remove glove box. D Refer to Instrument Panel Assembly in Body and
8. Remove attaching screws.
D Remove the four attaching screws.
865RS009
10. Remove control lever assembly.

865RS010
11. Remove control cable.
9. Pull the control lever assembly out and disconnect the
fan switch and air conditioning switch connectors. Installation
1. Adjust the control cable.
865RY00013
D Air source control cable. 2. Connect the control cable at the “COLD”
1. Slide the control lever to the left (“CIRC” position of the temperature control link of the
position). heater unit and secure it with the clip.
2. Connect the control cable at the “CIRC” position D Air select control cable
of the link unit of the blower assembly and 1. Turn the control knob to the right (“DEFROST”
secure it with the clip. position).
D Temperature control cable. 2. Connect the control cable at the “DEFROST”
1. Turn the control knob to the left (“MAX COLD” position of the mode control link of the heater
position). unit and secure it with the clip.
2. Check the control cable operation.
Control Panel Illumination Bulb

Control Panel Illumination Bulb and Associated Parts
865RS007
Legend (2) Bulb Socket

(1) Control Lever Assembly (3) Illumination Bulb
Removal
3. Pull out the bulb socket from the panel by turning it
counterclockwise.
4. Pull the illumination bulb from the socket.
Installation
Resistor
Resistor and Associated Parts
874RW005
Legend (5) Front Console

(1) Glove Box (6) Lower Cluster
(2) Duct (Heater only) (7) Instrument Panel Passenger Lower Cover
(3) Resistor Connector Assembly
(4) Resistor
2. Remove front console.
3. Remove lower cluster.
4. Remove glove box.
5. Remove instrument panel passenger lower cover
assembly.
6. Remove resistor connector.
7. Remove duct (heater only).
8. Remove resistor.
Air Conditioning System
General Description
Air Conditioning Refrigerant Cycle Construction
C01RS003
Legend (9) Condenser

(1) Electronic Thermostat (10) Compressor
(2) Evaporator Core (11) Magnetic Clutch
(3) Evaporator Assembly (12) Mode (HEAT) Control Door
(4) Temperature Sensor (13) Temp. Control Door (Air Mix Door)
(5) Expansion Valve (14) Heater Core
(6) Blower Motor (15) Mode (VENT) Control Door
(7) Dual Pressure Switch (16) Heater Unit
(8) Receiver/Drier (17) Mode (DEF) Control Door
The refrigeration cycle includes the following four Evaporation

processes as the refrigerant changes repeatedly from The refrigerant is changed from a liquid to a gas inside the
liquid to gas and back to liquid while circulating. evaporator. The refrigerant mist that enters the
evaporator vaporizes readily. The liquid refrigerant This vehicle is equipped with six-cylinder axle plate
removes the required quantity of heat (latent heat of compressor (1).
vaporization) from the air around the evaporator core The specified amount of the compressor oil is 240cc
cooling fins and rapidly vaporizes. Removing the heat (8.0 fl. oz.).
cools the air, which is then radiated from the fins and The oil used in the HFC-134a system compressor differs
lowers the temperature of the air inside the vehicle. from that used in R-12 systems.
The refrigerant liquid sent from the expansion valve and Also, compressor oil to be used varies according to the
the vaporized refrigerant gas are both present inside the compressor model. Be sure to avoid mixing two or more
evaporator as the liquid is converted to gas. different types of oil.
With this change from liquid to gas, the pressure inside If the wrong oil is used, lubrication will be poor and the
the evaporator must be kept low enough for vaporization compressor will seize or malfunction.
to occur at a lower temperature. Because of that, the The magnetic clutch connector is a waterproof type.
vaporized refrigerant is sucked into the compressor.
Magnetic Clutch
Compression The compressor is driven by the drive belt from the crank
The refrigerant is compressed by the compressor until it is pulley of the engine. If the compressor is activated each
easily liquefied at normal temperature. time the engine is started, this causes too much load to
The vaporized refrigerant in the evaporator is sucked into the engine. The magnetic clutch (3) transmits the power
the compressor. This action maintains the refrigerant from the engine to the compressor and activates it when
inside the evaporator at a low pressure so that it can the air conditioning is ON. Also, it cuts off the power from
easily vaporize, even at low temperatures close to the engine to the compressor when the air conditioning is
0°C(32°F). OFF. Refer to Compressor in this section for magnetic
Also, the refrigerant sucked into the compressor is clutch repair procedure.
compressed inside the cylinder to increase the pressure
and temperature to values such that the refrigerant can
easily liquefy at normal ambient temperatures.
Condensation
The refrigerant inside the condenser is cooled by the
outside air and changes from gas to liquid.
The high temperature, high pressure gas coming from the
compressor is cooled and liquefied by the condenser with
outside air and accumulated in the receiver/drier. The
heat radiated to the outside air by the high temperature,
high pressure gas in the compressor is called heat of
condensation. This is the total quantity of heat (heat of
vaporization) the refrigerant removes from the vehicle
interior via the evaporator and the work (calculated as the
quantity of heat) performed for compression.
Expansion
The expansion valve lowers the pressure of the
refrigerant liquid so that it can easily vaporize. 852RW002
The process of lowering the pressure to encourage

Condenser
vaporization before the liquefied refrigerant is sent to the
evaporator is called expansion. In addition, the expansion Also, it functions to cool and liquefy the high-pressure and
valve controls the flow rate of the refrigerant liquid while high-temperature vapor sent from the compressor by the
decreasing the pressure. radiator fan or outside air.
That is, the quantity of refrigerant liquid vaporized inside A condenser may malfunction in two ways: it may leak, or
the evaporator is determined by the quantity of heat which it may be restricted. A condenser restriction will result in
must be removed at a prescribed vaporization excessive compressor discharge pressure. If a partial
temperature. It is important that the quantity of refrigerant restriction is present, the refrigerant expands after
be controlled to exactly the right value. passing through the restriction.
Thus, ice or frost may form immediately after the
Compressor restriction. If air flow through the condenser or radiator is
The compressor performs two main functions: blocked, high discharge pressures will result. During
It compresses low-pressure and low-temperature normal condenser operation, the refrigerant outlet line will
refrigerant vapor from the evaporator into high-pressure be slightly cooler than the inlet line.
and high-temperature refrigerant vapor to the condenser. The vehicle is equipped with the parallel flow type
It pumps refrigerant and refrigerant oil through the air condenser. A larger thermal transmission area on the
conditioning system. inner surface of the tube allows the radiant heat to
increase and the ventilation resistance to decrease.
The refrigerant line connection has a bolt at the block
joint, for easy servicing.
The condenser assembly (6) is located in front of the
radiator. It provides rapid heat transfer from the
refrigerant to the cooling fins.
875RW004
Pressure Switch
The pressure switch (Dual pressure switch) (4) is
installed on the upper part of the receiver/drier, to detect
875RW004
excessively high pressure (high pressure switch) and
prevent compressor seizure due to the refrigerant leaking
Receiver / Drier (low pressure switch), so that the compressor is able to be
The receiver/drier (5) performs four functions: turned “ON” or “OFF”.
D As the quantity of refrigerant circulated varies The pressure characteristics of HFC-134a refrigerant
depending on the refrigeration cycle conditions, differ from those of R-12. Thus, the pressure switch
sufficient refrigerant is stored for the refrigeration operation for HFC-134a systems has been changed from
cycle to operate smoothly in accordance with R-12.
fluctuations in the quantity circulated. ON OFF
D The liquefied refrigerant from the condenser is mixed Compressor
(kPa/psi) (kPa/psi)
with refrigerant gas containing air bubbles. If
refrigerant containing air bubbles. Is sent to the Low-pressure 186.3±29.4 176.5±19.6
expansion valve, the cooling capacity will decrease control (27.0±4.3) (25.6±2.8)
considerably. Therefore, the liquid and air bubbles are High-pressure 2353.6±196.1 2942.0±196.1
separated and only the liquid is sent to the expansion control (341.3±28.4) (426.6±28.4)
valve.
D The receiver/drier utilizes a filter and drier to remove
the dirt and water mixed in the cycling refrigerant.
D The sight glass, installed on top of the receiver/drier,
shows the state of the refrigerant.
A receiver/drier may fail due to a restriction inside the
body of the unit. A restriction at the inlet to the
receiver/drier will cause high pressure.
Outlet restrictions will be indicated by low pressure and
little or no cooling. An excessively cold receiver/drier
outlet may indicate a restriction.
The receiver/drier of this vehicle is made of aluminum
with a smaller tank. It has a 300cc refrigerant capacity.
The refrigerant line connection has a bolt at the block
joint, for easy servicing.
875RW004
Expansion Valve Evaporator
This expansion valve (1) is an external pressure type and The evaporator cools and dehumidifies the air before the
it is installed at the evaporator intake port. air enters the passenger compartment. High-pressure
The expansion valve converts the high pressure liquid liquid refrigerant flows through the expansion valve (2)
refrigerant sent from the receiver/drier to a low pressure into the low-pressure area of the evaporator. The heat in
liquid refrigerant by forcing it through a tiny port before the air passing through the evaporator core (1) is lost to
sending it to the evaporator (2). the cooler surface of the core, thereby cooling the air.
This type of expansion valve consists of a temperature As heat is lost between the air and the evaporator core
sensor, diaphragm, ball valve, ball seat, spring surface, moisture in the vehicle condenses on the outside
adjustment screw, etc. surface of the evaporator core and is drained off as water.
The temperature sensor contacts the evaporator outlet When the evaporator malfunctions, the trouble will show
pipe, and converts changes in temperature to pressure. It up as an inadequate supply of cool air. The cause is
then transmits these to the top chamber of the typically a partially plugged core due to dirt, or a
diaphragm. malfunctioning blower motor.
The refrigerant pressure is transmitted to the diaphragm’s The evaporator core with a laminate louver fin is a
bottom chamber through the external equalizing pressure single-sided tank type where only one tank is provided
tube. under the core.
The ball valve is connected to the diaphragm. The
opening angle of the expansion valve is determined by
the force acting on the diaphragm and the spring
pressure.
The expansion valve regulates the flow rate of the
refrigerant. Accordingly, when a malfunction occurs to
this expansion valve, both discharge and suction
pressure get low, resulting in insufficient cooling capacity
of the evaporator.
The calibration has been changed to match the
characteristics of HFC-134a.
874RY00007
Electronic Thermostat
The thermostat consists of the thermo sensor (1) and
thermostat unit (4) which functions electrically to reduce
the noises being generated while the system is in
operation.
The electronic thermo sensor (1) is mounted at the
evaporator core (2) outlet and senses the temperature of
the cool air from the evaporator (3). Temperature signals
are input to the thermostat unit. This information is
874RY00003 compared by the thermo unit and results in the output to
operate the A/C thermostat relay and turn the magnetic
clutch ON or OFF to prevent evaporator freeze-up.
A characteristic of the sensor is that the resistance Refrigerant Line
decreases as the temperature increases and the Restriction in the refrigerant line will be indicated by:
resistance increases as the temperature decreases.
1. Suction line — A restricted suction line will cause low
suction pressure at the compressor, low discharge
pressure and little or no cooling.
2. Discharge line — A restriction in the discharge line
generally will cause the discharge line to leak.
3. Liquid line — A liquid line restriction will be evidenced
by low discharge and suction pressure and
insufficient cooling.
Refrigerant flexible hoses that have a low permeability to
refrigerant and moisture are used. These low
permeability hoses have a special nylon layer on the
inside.
874RX022
852RW011
Legend
(1) Pressure Resistance Layer (Polyester Braid)
(2) Moisture Resistance AND Outer Protector
Layer
(3) Heat Resistance Layer
(4) Heat Resistance Core Layer (Neoprene)
(5) Low Permeation Layer (Nylon Barner)
Air Conditioning Parts
852RW009
Legend (7) Condenser Assembly

(1) Liquid Line (High-Pressure Pipe) (8) Drive Belt
(2) O-ring (9) Relay
(3) Compressor (10) Drain Hose
(4) Discharge Line (High-Pressure Hose) (11) Suction Line (Low-Pressure Hose)
(5) Pressure Switch (12) Evaporator Assembly
(6) Receiver Drier (13) A/C Switch
Wiring Diagram
D08RW254
D08RX003
D08RW256
Diagnosis
Air Conditioning Cycle Diagnosis
No cooling or insufficient cooling. Magnetic clutch does not run. Refer to “Magnetic Clutch Diagnosis”
in this section.
Compressor is not rotating properly. Adjust the drive belt to the specified
Drive belt is loose or broken. tension or replace the drive belt.
Compressor is not rotating properly. Clean the magnetic clutch face or
Magnetic clutch face is not clean and replace.
slips.
Compressor is not rotating properly. Adjust the clearance. Refer to
Incorrect clearance between Compressor in this section.
magnetic drive plate and pulley.
Compressor is not rotating properly. Replace the compressor
Compressor oil leaks from the shaft
seal or shell.
Compressor is seized.
Insufficient or excessive charge of Discharge and recover the
refrigerant. refrigerant. Recharge to the
specified amount.
Leaks in the refrigerant system. Check the refrigerant system for
leaks and repair as necessary.
Discharge and recover the
refrigerant. Recharge to the
specified amount.
Condenser is clogged or insufficient Clean the condenser or replace as
radiation. necessary.
Temperature control link unit of the Repair the link unit.
heat unit is defective.
Unsteady operation due to a foreign Replace the expansion valve.
substance in the expansion valve.
Poor operation of the electronic Check the electronic thermostat and
thermostat. replace as necessary.
Insufficient velocity of cooling air. Evaporator clogged or frosted. Check the evaporator core and
replace or clean the core.
Air leaking from the cooling unit or air Check the evaporator and duct
duct. connection, then repair as
necessary.
Blower motor does not rotate Refer to Fan Control Knob (Fan
properly. Switch) Diagnosis in this section.
*For the execution of the charging and discharging
operation in the table above, refer to Recovery,
Recycling, Evacuating and Charging in this section.
Checking The Refrigerant System With
Manifold Gauge
Since Refrigerant-134a (HFC-134a) is used in the air
conditioning system in this vehicle, be sure to use
manifold gauges, charging hoses and other air
conditioning service tools for HFC-134a when
checking the refrigerant system.
Conditions:
D Run the engine at idling
D Air conditioning switch is “ON”
D Run the blower motor at “HIGH” position
D Temperature control lever set to “MAX COLD”
D Air source selector lever at “CIRC”
D Open the engine hood
D Close all the doors
Normal Pressure:
D At ambient temperature: approx. 25–30°C
(77–86°F).
D At low-pressure side: approx. 147.1–294.2 kPa
(21.3–42.7 psi).
D At high-pressure side: approx. 1372.9–1863.3 kPa
(199.1–270.2 psi).
Refer to the table on the refrigerant pressure-temperature
relationship in this section.
HFC-134a Pressure-Temperature Relationship
Pressure Temperature
(kPa) (psi) (°C) (°F)
36 5.3 –20 –4.4
67 9.7 –15 5
104 15 –10 14
147 21 –5 23
196 28 0 32
255 37 5 41
314 45 10 50
392 57 15 59
471 68 20 68
569 82 25 77
677 98 30 86
785 114 35 95
912 132 40 104
1059 154 45 113
1216 176 50 122
Connect The Manifold Gauge
Low-pressure hose (LOW) — Suction side
High pressure hose (HI) — Discharge side
901RS137
Legend
(1) Low Side
(2) High Side

Discharge (High Gauge) Pressure Condenser clogged or dirty. Clean the condenser fins
Abnormally High
Cooling fan does not operate Check the cooling fan operation.
properly.
Discharge (High Gauge) Pressure Excessive refrigerant in system. Discharge and recover refrigerant.
Abnormally High. Recharge to specified amount.
Insufficient cooling.
Discharge (High Gauge) Pressure Air in system. Evacuate and charge refrigerant
Abnormally High. system.
High pressure gauge drop. (After
stopping A/C, the pressure drops
approx. 196 kPa (28 psi) quickly)
Discharge (High Gauge) Pressure Insufficient refrigerant in system. Check for leaks. Discharge and
Abnormally Low. recover the refrigerant. Recharge to
Insufficient cooling the specified amount.
Discharge (High Gauge) Pressure Clogged or defective expansion Replace the expansion valve.
Abnormally Low. valve.
Low pressure gauge indicates
vacuum.

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

Suction (Low Gauge) and Discharge Excessive refrigerant in system. Discharge and recover the
(High Gauge) Pressure Abnormally refrigerant, the Recharge to the
High. specified amount.
Insufficient cooling. Condenser clogged or dirty. Clean the condenser fins.
Suction (Low Gauge) and Discharge Air in system. Evacuate and charge refrigerant.
(High Gauge) Pressure Abnormally
High.
Suction (Low) pressure hose (Not
cold).
Suction (Low Gauge) and Discharge Insufficient refrigerant in system. Check for leaks. Discharge and
(High Gauge) Pressure Abnormally recover refrigerant. Recharge to
Low. specified amount.
Insufficient cooling
A/C — Air Conditioning
Magnetic Clutch Diagnosis
D08RX004
When the air conditioning switch and the fan control knob flows through the thermostat and the compressor relay to
(fan switch) are turned on with the engine running, current activate the magnetic clutch.
The air conditioning can be stopped by turning off the air in the prearranged conditions to reduce the engine load
conditioning switch or the fan control knob (fan switch). which is being caused by the rise in the engine coolant
However, even when the air conditioning is in operation, temperature, and the acceleration of the vehicle, etc.
the electronic thermostat, the pressure switch or the For the inspection of the relays, switches and units in the
Powertrain Control Module (PCM) is used to stop the air table, refer to “Individual Inspection” in this section.
conditioning temporarily by turning off the magnetic clutch
Magnetic Clutch Does Not Run

Step Action Yes No
1 Are No. C-20 (10A) fuse and No. C-19 (25A) fuse OK? Go to Step 2 Replace
2 Are heater and A/C (B-36), thermostat (X-5), and compressor
(X-7) relays OK? Go to Step 3 Replace
3 Is pressure switch (dual pressure switch) OK? Switch defective
or insufficient
Go to Step 4 refrigerant.
4 Are air conditioning switch and fan control knob (Fan Switch) OK? Go to Step 5 Replace
5 1. Turn the ignition switch “ON” (Engine is running).
2. Air conditioning switch and fan control knob (Fan Switch)
“ON”.
3. Check to see if battery voltage is present at chassis side
connector terminal No. E3-1.
Is there a battery voltage? Go to Step 6 Go to Step 7
6 Check to see if continuity between compressor side connector
terminal No. E3-1 and the magnetic clutch side connector
terminal.
Magnetic clutch Compressor
Is there a continuity? defective. defective.
7 Check to see if battery voltage is present at chassis side Open circuit
connector terminal No. C25-1 between No.C-20
(10A) fuse and
Go to Step 8 No. C25-1.
8 1. Disconnect thermostat relay (X-5).
Open circuit
2. Check to see if battery voltage is present at the chassis side
between No.
relay terminal NO. X5-2
C25-2 and
Is there a battery voltage? Go to Step 9 No.X5-2.
9 Check to see if voltage (approx. 10V) is present between chassis
side relay terminal No. X5-1 and No. X5-3.
10 1. Reconnect thermostat relay and disconnect compressor relay
(X-7).
Open circuit
between No.
relay terminal No. X7-2.
X5-4 and No.
Is there a battery voltage? Go to Step 11 X7-2.
11 Check to see if continuity between chassis side relay terminal No.
X7-4 and the chassis side connector terminal No. E3-1.
Is there a continuity? Go to Step 12 Open circuit.
12 Check to see if battery voltage is present between chassis side
relay terminal No. X7-1 and No. X7-3.
13 Check to see if battery voltage is present at chassis side relay Open circuit
terminal No. X7-1. between No.
C-20 (10A) fuse
Go to Step 15 and No. X7-1.
Magnetic Clutch Does Not Run (Cont’d)

Step Action Yes No
14 Check to see if battery voltage is present at chassis side Power train
connector terminal No. C1-B14. control module
(PCM) defective.
Refer to Open circuit
Driveability and between No.
Emissions in X7-3 and No.
Engine section. C1-B14.
15 Check to see if continuity between chassis side relay terminal No. Power train
X-54 and chassis side connector terminal No. C3-E15. control module
(PCM) defective.
Is there a continuity?
Refer to
Driveability and
Emissions in
Engine section. Open circuit
16 Check to see if battery voltage is present at chassis side relay
terminal No. X5-1.
17 1. Reconnect thermostat relay.
Open circuit
connector terminal No. B4-3.
between No.I23-6
Is there a battery voltage? Go to Step 18 and No.B4-3.
18 Check to see if battery voltage (appox 10V) is present at chassis Open circuit
side connector terminal No. B4-1. between No.
X5-3 and No.
Go to Step 19 B4-1.
19 Check to see if continuity between chassis side connector Open circuit
terminal No. B4-2 and No. I18-4. between No.
B4-2 and No.
I18-4 or poor
Electronic ground (Fan
thermostat Switch Ground
defective. Circuit).
20 Check to see if battery voltage is present at chassis side Open circuit
connector terminal No. I23-2. Open circuit between No.
between X5-1 C-20 (10A) fuse
Is there a battery voltage? and No.I23-6. and No.I23-2.
Individual Inspection Heater And A/C (B-36), Thermostat (X-5)

And Compressor (X-7) Relay
Fan Control Knob (Fan Switch) And Air
Conditioning (A/C) Switch 1. Disconnect relays and check for continuity and
resistance between relay terminals.
1. Check for continuity between the fan switch and the D For handling of these relays, refer to Heater &A/C
A/C switch side connector terminals. Relay in this section.
865RS002
825RS003
Fan swtich Fan switch connector terminals with Relay terminals with
position continuity Condition
continuity
OFF No continuity Normal 1 – 3 (Approx 85–105W)
1 1–2–4 When battery voltage is
2–4
2 1–4–5 applied between 1 – 3
3 1–3–4
4 1–4–6
A/C switch A/C switch connector terminals with

position continuity
OFF 1–6
ON 1–2–6
Pressure Switch D When removing and replacing any parts which
require discharging the refrigerant circuit, the
1. Disconnect pressure switch connector and check for operations described in this section must be
continuity between pressure switch side connector performed in the following sequence:
terminals (1) and (2).
1. Use the J-39500 (ACR4: HFC-134a Refrigerant
Recovery / Recycling / Recharging / System) or
equivalent to thoroughly discharge and recover the
refrigerant.
2. Remove and replace the defective part.
3. After evacuation, charge the air conditioning
system and check for leaks.
Repair Of Refrigerant Leaks

Refrigerant Line Connections
Install new O-rings, if required. When disconnecting or
connecting lines, use two wrenches to prevent the
connecting portion from twisting or becoming damaged.
875RW003
General Repair Procedure

Precautions For Replacement or Repair of
There are certain procedures, practices and precautions
that should be followed when servicing air conditioning
systems:
D Keep your work area clean.
D Always wear safety goggles and protective gloves
when working on refrigerant systems.
D Beware of the danger of carbon monoxide fumes
852RS003
caused by running the engine. When connecting the refrigerant line at a block joint,
D Beware of discharged refrigerant in enclosed or securely insert the projecting portion of the joint portion
improperly ventilated garages. into the connecting hole on the unit side and secure with a
D Always disconnect the negative battery cable and bolt. Apply the specified compressor oil to the O-rings
discharge and recover the refrigerant whenever prior to connecting.
repairing the air conditioning system.
D When discharging and recovering the refrigerant, do
not allow refrigerant to discharge too fast; it will draw
compressor oil out of the system.
D Keep moisture and contaminants out of the system.
When disconnecting or removing any lines or parts,
use plugs or caps to close the fittings immediately.
Never remove the caps or plugs until the lines or parts
are reconnected or installed.
D When disconnecting or reconnecting the lines, use
two wrenches to support the line fitting, to prevent
from twisting or other damage.
D Always install new O-rings whenever a connection is
disassembled.
D Before connecting any hoses or lines, apply new
specified compressor oil to the O-rings.
CAUTION: Compressor (PAG) oil to be used varies Insert the nut into the union.
according to the compressor model. Be sure to apply First, tighten the nut by hand as much as possible, then
oil specified for the model of compressor. tighten the nut to the specified torque.
850RW002 850RW004
O-rings (2) must be closely aligned with the raised portion

(1) of refrigerant line.
850RW003
Leak Check
Inspection of refrigerant leak Therefore, it is most important to repair refrigerant leak
Refrigerant leak may cause an adverse effect not only on when there is any leak found.
the performance and durability of each component of the
air-conditioner, but also on the global atmosphere.
Inspection flow of refrigerant leak

Step Action Yes No
1 1. Evacuate the refrigerant system.
2. Charge the refrigerant.
Repair refrigerant
Is there any refrigerant leak? system Go To Step 2
2 1. Operate the compressor for more than 5 minutes to raise the
Compressor
pressure on the high pressure side.
Repair refrigerant operation to be
Is there any refrigerant leak at high pressure components? system confirmed
Inspection steps D Welds of condenser body
Check the components of the air conditioner to see if Receiver drier
there occurs any refrigerant leak along the flow of
D Pipe connection
refrigerant.
D Attaching section of pressure switch
NOTE:
D Section around the sight glass
D To avoid an error in the detection of refrigerant leak,
Evaporator unit (cooling unit)
make sure there is no refrigerant vapor or cigarette
smoke around the vehicle before conducting the D Pipe connection
inspection. D Connections of expansion valve
Also, select a location where the refrigerant vapor will D Brazed sections of evaporator
not be blown off by wind.
NOTE:
D Inspection should be conducted chiefly on the pipe
connections and sections where a marked oil D The evaporator and expansion valve are contained in
contamination is found. the case. Remove the drain hose or the resistor of the
When refrigerant is leaking, oil inside is also leaking at cooling unit and insert a leak detector when checking
the same time. for any leak.
D It is not possible to visually check the leak from inside Flexible hose
the cooling unit. Follow the method below when D Pipe connection
checking. D Caulking section of the hose
Remove the drain hose or resistor of the cooling unit, D Hose (cracks, pinholes, flaws)
and insert a leak detector to see if there occurs any
leak. Pipe
High pressure side D Pipe connection
1. Discharger section of compressor D Pipe (cracks, flaws)
2. Inlet/outlet section of condenser Charge Valve
3. Inlet/outlet section of receiver driver NOTE:
4. Inlet section of cooling unit D The charge valve, which is used to connect the gauge
Low pressure side manifold, is normally provided with a resin cap. When
the valve inside gets deteriorated, refrigerant will leak
1. Outlet section of cooling unit out.
2. Intake section of compressor
Major checking points of refrigerant leak Leak at Refrigerant Line Connections
Compressor 1. Check the torque on the refrigerant line fitting and, if
too loose, tighten to the specified torque.
D Pipe connection
D Use two wrenches to prevent twisting and damage
D Sealing section of shaft
to the line.
D Mating section of cylinder
D Do not over tighten.
Condenser
2. Perform a leak test on the refrigerant line fitting.
D Pipe connection
3. If the leak is still present, discharge and recover the WARNING:
refrigerant from the system.
D SHOULD HFC-134A CONTACT YOUR EYE(S),
4. Replace the O-rings. CONSULT A DOCTOR IMMEDIATELY.
D O-rings cannot be reused. Always replace with new D DO NOT RUB THE AFFECTED EYE(S). INSTEAD,
ones. SPLASH QUANTITIES OF FRESH COLD WATER
D Be sure to apply the specified compressor oil to the OVER THE AFFECTED AREA TO GRADUALLY
new O-rings. RAISE THE TEMPERATURE OF THE
REFRIGERANT ABOVE THE FREEZING POINT.
5. Retighten the refrigerant line fitting to the specified
torque. D OBTAIN PROPER MEDICAL TREATMENT AS
SOON AS POSSIBLE. SHOULD THE HFC-134A
TOUCH THE SKIN, THE INJURY MUST BE
to the line.
TREATED THE SAME AS SKIN WHICH HAS BEEN
6. Evacuate, charge and retest the system. FROSTBITTEN OR FROZEN.
Leaks In The Hose Refrigerant Recovery
If the compressor inlet or outlet hose is leaking, the entire The refrigerant must be discharged and recovered by
hose must be replaced. The refrigerant hose must not be using the J-39500 (ACR4:HFC-134a Refrigerant
cut or spliced for repair. Recovery/Recycling/Recharging/System) or equivalent
1. Locate the leak. before removing or mounting air conditioning parts.
2. Discharge and recover the refrigerant. 1. Connect the high and low charging hoses of the
3. Remove the hose assembly. ACR4(or equivalent) as shown below.
D Cap the open connections at once.
4. Connect the new hose assembly.
D Use two wrenches to prevent twisting or damage to
the hose fitting.
D Tighten the hose fitting to the specified torque.
5. Evacuate, charge and test the system.
Compressor Leaks
If leaks are located around the compressor shaft seal or
shell, replace or repair the compressor.
Recovery, Recycling, Evacuation and

Charging of HFC-134a
Air conditioning systems contain HFC-134a. This is a
chemical mixture which requires special handling
procedures to avoid personal injury.
D Always wear safety goggles and protective gloves.
D Always work in a well-ventilated area. Do not weld or
steam clean on or near any vehicle-installed air
conditioning lines or components.
D If HFC-134a should come in contact with any part of
the body, flush the exposed area with cold water and
immediately seek medical help.
D If it is necessary to transport or carry any container of
HFC-134a in a vehicle, do not carry it in the
passenger compartment.
D If it is necessary to fill a small HFC-134a container
from a large one,never fill the container completely. 901RS141
Space should always be allowed above the liquid for

Legend
expansion.
(1) Low Side
D HFC-134a and R-12 should never be mixed as their
(2) High Side
compositions are not the same.
D HFC-134a PAG oil tends to absorb moisture more 2. Recover the refrigerant by following the
quickly than R-12 mineral oil and, therefore, should Manufacturer’s Instructions.
be handled more carefully.
3. When a part is removed, put a cap or a plug on the
D Keep HFC-134a containers stored below 40°C connecting portion so that dust, dirt or moisture
(100°F). cannot get into it.
Refrigerant Recycling 8. If no leaks are found, again operate the vacuum pump
Recycle the refrigerant recovered by J-39500 for 20 minutes or more. After confirming that the
gauge manifold pressure is at 750 mmHg (30 inHg),
(ACR4:HFC-134a Refrigerant Recovery / Recycling /
close both hand valves.
Recharging / System) or equivalent.
For the details of the actual operation, follow the steps in 9. Close positive shutoff valve. Stop the vacuum pump
the ACR4(or equivalent) Manufacturer’s Instructions. and disconnect the center hose from the vacuum
pump.
Evacuation of The Refrigerant System
Charging The Refrigerant System
There are various methods of charging refrigerant into the
air conditioning system.
These include using J-39500 (ACR4:HFC-134a
Refrigerant Recovery/Recycling/Recharging/System) or
equivalent and direct charging with a weight scale
charging station.
Charging Procedure
D ACR4(or equivalent) Method
For the charging of refrigerant recovered by ACR4(or
equivalent), follow the manufacturer’s instruction.
901RS142
Legend
(1) Low Side
(2) High Side
NOTE: Explained below is a method using a vacuum

pump. Refer to the ACR4(or equivalent) manufacturer’s
instructions when evacuating the system with a ACR4(or
equivalent).
Air and moisture in the refrigerant will cause problems in
the air conditioning system. Therefore, before charging
the refrigerant, be sure to evacuate air and moisture thor-
oughly from the system.
1. Connect the gauge manifold.
D High-pressure valve (HI) — Discharge-side.
D Low-pressure valve (LOW) — Suction-side.
2. Discharge and recover the refrigerant.
3. Connect the center hose of the gauge manifold set to
the vacuum pump inlet.
4. Operate the vacuum pump, open shutoff valve and
then open both hand valves. 901RS141
5. When the low-pressure gauge indicates Legend

approximately 750 mmHg (30 inHg), continue the (1) Low Side
evacuation for 5 minutes or more. (2) High Side
6. Close both hand valves and stop the vacuum pump.
7. Check to ensure that the pressure does not change D Direct charging with a weight scale charging
after 10 minutes or more. station method
D If the pressure changes, check the system for 1. Make sure the evacuation process is correctly
leaks. completed.
D If leaks occur, retighten the refrigerant line 2. Connect the center hose of the manifold gauge to the
connections and repeat the evacuation steps. weight scale.
3. Connect the low pressure charging hose of the
manifold gauge to the low pressure side service valve
of the vehicle.
4. Connect the high pressure charging hose of the
manifold gauge to the high pressure side service
valve of the vehicle.
901RS144
6. Perform a system leak test:

D Charge the system with approximately 200 g
(0.44 lbs) of HFC-134a.
D Make sure the high pressure valve of the manifold
gauge is closed.
D Check to ensure that the degree of pressure does
not change.
D Check for refrigerant leaks by using a HFC-134a
leak detector.
D If a leak occurs, recover the refrigerant. Repair the
leak and start all over again from the first step of
evacuation.
7. If no leaks are found, continue charging refrigerant to
the air conditioning system.
901RS143 D Charge the refrigerant until the scale reading
Legend decreases by the amount of the charge specified.
(1) Low Side Specified amount: 600 g (1.32 lbs)
(2) High Side D If charging the system becomes difficult:
(3) Refrigerant Container
1. Run the engine at idle and close all the vehicle
(4) Weight Scale
doors.
5. Place the refrigerant container(3) up right on a weight 2. Turn A/C switch “ON”.
scale(4). 3. Set the fan switch to its highest position.
Note the total weight before charging the refrigerant. 4. Set the air source selector lever to “CIRC”.
a. Open the refrigerant container valve. 5. Slowly open the low side valve on the manifold
b. Open the low side vale on the manifold gauge set. gauge set.
Refer to the manufacturer’s instructions for a WARNING: BE ABSOLUTELY SURE NOT TO OPEN
weight scale charging station. THE HIGH PRESSURE VALVE OF THE MANIFOLD
GAUGE. SHOULD THE HIGH PRESSURE VALVE BE
OPENED, THE HIGH PRESSURE REFRIGERANT
WOULD FLOW BACKWARD, AND THIS MAY CAUSE
THE REFRIGERANT CONTAINER TO BURST.
8. When finished with the refrigerant charging, close the
low pressure valve of the manifold gauge and
container valve.
9. Check for refrigerant leaks.
Checking The A/C System
1. Run the engine and close all the vehicle doors.
2. Turn A/C switch “ON”, set the fan switch to its highest
position.
3. Set the air source lever to “CIRC”, set the
temperature lever to the full cool position.
4. Check the high and low pressure of the manifold
gauge.
D Immediately after charging refrigerant, both high
and low pressures might be slightly high, but they
settle down to the pressure guidelines shown
below:
D The ambient temperature should be between
25–30°C (77–86°F).
D The pressure guideline for the high-pressure side is
approximately 1372.9–1863.3 kPa (199.1–270.2
psi).
D The pressure guideline for the low-pressure side is
approximately 147.1–294.2 kPa (21.3–42.7 psi).
D If an abnormal pressure is found, refer to Checking
The Refrigerant System With Manifold Gauge in
this section.
5. Put your hand in front of the air outlet and move the
temperature control lever of the control panel to
different positions. Check if the outlet temperature
changes as selected by the control knob.
Compressor Assembly
Compressor Assembly and Associated Parts
852RW010
Legend (3) Refrigerant Line Connector

(1) Compressor Bracket (4) Compressor
(2) Seal Washer (5) Drive Belt
Removal 2. Discharge and recover refrigerant

3. Disconnect magnetic clutch harness connector.
4. Remove drive belt. 4. Connect magnetic clutch harness connector.
D Move drive belt tensioner to loose side using
wrench then remove drive belt.
850RY00001
Legend
(1) Auto Tensioner
(2) Idle Pulley
(3) Cooling Fan Pulley
(4) Drive Belt
(5) Power Steering Oil Pump
(6) Air Conditioner Compressor
(7) Crankshaft Pulley
(8) Generator
5. Disconnect refrigerant line connector.

D When removing the line connector, the connecting
part should immediately be plugged or capped to
prevent foreign matter from being mixed into the
line.
6. Remove compressor.
Installation
1. Install compressor.
D Tighten the compressor fixing bolts to the specified
torque.
Torque: 19 N•m (14 lb•ft)
2. Connect refrigerant line connector.
D Tighten the refrigerant line connector fixing bolts to
the specified torque.
D O-rings cannot be reused. Always replace with new
ones.
D Be sure to apply new compressor oil to the O-rings
when connecting refrigerant lines.
3. Install drive belt.
D Move serpentine belt tensioner to loose side using
wrench, then install serpentine belt to normal
position.
Condenser Assembly
Condenser Assembly and Associated Parts
875RY00005
Legend (4) Radiator Grille

(1) Refrigerant Line (5) Engine Hood Front End Stay
(2) Pressure Switch Connector (6) Condenser Assembly
(3) Front Bumper Assembly
1. Disconnect the battery ground cable. 1. Install condenser assembly.
2. Discharge and recover refrigerant. D If installing a new condenser, be sure to add 30cc
D Refer to Refrigerant Recovery in this section. (1.0 fl. oz.) of new compressor oil to a new one.
3. Remove radiator grille. D Tighten the condenser fixing bolts to the specified
4. Remove front bumper assembly. torque.
D Refer to Bumpers in Body and Accessories section. Torque: 6 N•m (52 lb•in)
5. Remove engine hood front end stay. 2. Connect refrigerant line.
6. Disconnect pressure switch connector. D Tighten the inlet line connector fixing bolt to the
7. Disconnect refrigerant line. specified torque.
D When removing the line connector, the connecting Torque: 15 N•m (11 lb•ft)
part should immediately be plugged or capped to D Tighten the outlet line connector fixing bolt to the
prevent foreign matter from being mixed into the specified torque.
line.
8. Remove condenser assembly. Torque: 6 N•m (52 lb•in)
D Handle with care to prevent damaging the D O-rings cannot be reused. Always replace with new
condenser or radiator fin. ones.
D Be sure to apply new compressor oil to the O-rings 4. Install engine hood front end stay.
when connecting the refrigerant line. 5. Install front bumper assembly.
3. Connect pressure switch connector. 6. Install radiator grille.
Receiver / Drier
Receiver / Drier and Associated Parts
875RY00004
Legend (3) Receiver / Drier

(1) Pressure Switch Connector (4) Radiator Grille
(2) Refrigerant Line (5) Bracket Bolt
1. Disconnect the battery ground cable. To install, follow the removal steps in the reverse order,
2. Discharge and recover refrigerant.
1. If installing a new receiver/drier, be sure to add 30cc
(1.0 fl. oz.) of new compressor oil to a new one.
3. Remove radiator grille.
2. Put the receiver/drier in the bracket and connect with
4. Disconnect pressure switch connector. the refrigerant line. Check that no excessive force is
5. Disconnect refrigerant line. imposed on the line. Fasten the bracket bolt to the
D When removing the line connected part, the receiver/drier.
connecting part should immediately be plugged or 3. Tighten the refrigerant line to the specified torque.
capped to prevent foreign matter from being mixed Torque: 6 N•m (52 lb•in)
into the line.
4. O-rings cannot be reused. Always replace with new
6. Remove bracket bolt.
ones.
7. Remove receiver/drier.
5. Be sure to apply new compressor oil to the O-rings
D Loosen the bolt, then, using care not to touch or when connecting the refrigerant line.
bend the refrigerant line, carefully pull out the
receiver/drier.
Pressure Switch
Pressure Switch and Associated Parts
875RY00006
Legend (2) Pressure Switch

(1) Pressure Switch Connector (3) Radiator Grille
1. O-ring cannot be reused. Always replace with a new
D Refer to “Refrigerant Recovery in this section.
one.
2. Be sure to apply new compressor oil to the O-ring
4. Disconnect pressure switch connector. when connecting pressure switch.
5. Disconnect pressure switch. 3. Tighten the pressure switch to the specified torque.
D When removing the switch connected part, the Torque: 13 N•m (113 lb•in)
connecting part should immediately be plugged or
capped to prevent foreign matter from being mixed
into the line.
Evaporator Assembly
Evaporator Assembly and Associated Parts
874RT002
Legend (5) Instrument Panel Passenger Lower Cover

(1) Resistor and Electronic Thermostat Connector Assembly
(2) Drain Hose (6) Glove Box
(3) Refrigerant Line (7) Front Console Assembly
(4) Passenger Knee Bolster Reinforcement (8) Lower Cluster Assembly
Assembly (9) Evaporator Assembly
Removal
3. Remove front console assembly.
6. Remove instrument panel passenger lower cover
assembly.
7. Remove passenger knee bolster reinforcement
assembly.
8. Disconnect resistor (2) and electronic thermostat
connector (1).
874RY00009
9. Disconnect drain hose. 1. To install a new evaporator assembly, add 50cc
10. Disconnect refrigerant line. (1.7 fl. oz.) of new compressor oil to the new core.
D Use a back-up wrench when disconnecting and 2. Tighten the refrigerant outlet line to the specified
reconnecting the refrigerant lines. torque.
D When removing the refrigerant line connected part, Torque: 25 N•m (18 lb•ft)
the connecting part should immediately be plugged 3. Tighten the refrigerant inlet line to the specified
or capped to prevent foreign matter from being torque.
mixed into the line.
11. Remove evaporator assembly.
ones.
Installation 5. Be sure to apply new compressor oil to the O-rings
To install, follow the removal steps in the reverse order, when connecting lines.
Electronic Thermostat, Evaporator Core and/or Expansion Valve

Disassembled View
874RX017
Legend (6) Attaching Screw

(1) Lining (7) Lining
(2) Expansion Valve (8) Evaporator Core
(3) O-ring (9) Electronic Thermostat
(4) Evaporator Assembly (10) Upper Case
(5) Lower Case
Removal 2. Discharge and recover refrigerant.

4. Remove the electronic thermostat sensor fixing clip.
Pull the sensor from the evaporator assembly.
5. Remove clip.
7. Remove upper case.
D Slit the case parting face with a knife since the lining
is separated when removing the evaporator.
874RY00006
10. Remove expansion valve.

D Tear off the insulator carefully.
D Remove the sensor fixing clip.
D Use a back-up wrench when disconnecting all
refrigerant pipes.
Installation
874RS006 1. The sensor is installed on the core with the clip.
D Lift to remove the upper case. 2. The sensor must not interfere with the evaporator
core.
3. When installing the new evaporator core, install the
thermo sensor (2) to the evaporator core (1) specified
position with the clip in the illustration.
874RY00005
9. Remove evaporator core.
874RX021

ones.
when connecting lines.
6. Be sure to install the sensor and the insulator on the 8. Tighten the refrigerant lines to the specified torque.
place where they were before. Refer to Main Data and Specifications for Torque
7. To install a new evaporator core, add 50cc (1.7 fl. oz.) Specifications in this section.
of new compressor oil to the new core. 9. Apply an adhesive to the parting face of the lining
when assembling the evaporator assembly.
Air Conditioning Switch and Illumination Bulb

Air Conditioning Switch, Illumination Bulb and Associated Parts
865RS003
Legend (2) Illumination Bulb

(1) Control Lever Assembly (3) A/C Switch
Removal 4. Turn the illumination bulb counterclockwise to

remove.
Installation
3. Lift up the catch portion (1) of the switch and remove
the air conditioning switch (2) while pushing it toward
the outside.
865RS004
Refrigerant Line
Refrigerant Line and Associated Parts
852RY00013
Legend (4) Discharge Line (High Pressure Hose)

(1) Clip and Clamp (5) Air Cleaner
(2) Suction Line (Low Pressure Hose) (6) Radiator Grille
(3) Liquid Line (High-Pressure Pipe) (7) Suction Line (Low-Pressure Pipe)
Removal 7. Disconnect suction line (Low-pressure pipe) using a

back-up wrench.
1. Disconnect the battery ground cable. 8. Disconnect suction line (Low-pressure hose) using a
2. Discharge and recover refrigerant. back-up wrench.
D Refer to Refrigerant Recovery in this section. 9. Disconnect discharge line (High-pressure hose)
3. Remove radiator grille. using a back-up wrench.
4. Remove air cleaner. D Use a backup wrench when disconnecting and
5. Remove clip and clamp. reconnecting the refrigerant lines.
6. Disconnect liquid line (High-pressure pipe).
D When removing the refrigerant line connecting part,
the connecting part should immediately be plugged
or capped to prevent foreign matter from being
Installation
ones.
when connecting lines.
3. Tighten the refrigerant line to the specified torque.
Refer to Main Data and Specifications for Torque
Specifications in this section.
Main Data And Specifications

General Specifications
HEATER UNIT
Temperature control Reheat air mix system
Capacity 4.3 kw (3,700 Kcal./hr.)
Air flow 280 m#/hr
HEATER CORE
Type Plate and corrugate fin type
Element dimension 171 mm (6.7 in.) × 161 mm (6.3 in.) × 25 mm (0.98 in.)
Radiating area Approx. 0.75 m@
EVAPORATOR ASSEMBLY
Capacity 4.9 kw (4,200 Kcal./hr.)
Air flow 470 m#/hr
EVAPORATOR CORE
Type Al-laminate louver fin type
Element dimension 235 mm (9.3 in.) × 225.3 mm (8.9 in.) × 60 mm (2.4 in.)
EXPANSION VALVE
Type Internal pressure equalizer type
THERMOSTAT SWITCH
Type Electronic thermostat
OFF: Below 3.5 ± 0.5 °C (38.3 ± 0.9 °F)
ON: Above 5.0 ± 0.5 °C (41.0 ± 0.9 °F)
CONDENSER
Type Parallel flow
Radiation performance 15.9 kw (13,700 Kcal./hr.)
RECEIVER/DRIER
Type Assembly includes sight glass with dual pressure
switch
Internal volume 300 cc (10 fl.oz.)
PRESSURE SWITCH
Type Dual pressure switch
Low pressure control
ON: 186.3±29.4 kPa (27.0±4.3 psi)
OFF: 176.5±19.6 kPa (25.6±2.8 psi)
High pressure control
DIFF: 2353.6±196.1 kPa (341.3±28.4 psi)
OFF: 2942.0±196.1 kPa (426.6±28.4 psi)
REFRIGERANT
Type HFC-134a
Specified amount 600 g (1.32 lbs.)
Torque Specifications
852RW004
874RX016
Compressor
Service Precaution This compressor has a clutch driver design without torque
cushion (1).
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL
RESTRAINT SYSTEM (SRS). REFER TO THE SRS
COMPONENT LOCATION VIEW IN ORDER TO
DETERMINE WHETHER YOU ARE PERFORMING
SERVICE ON OR NEAR THE SRS COMPONENTS OR
THE SRS WIRING. WHEN YOU ARE PERFORMING
SERVICE ON OR NEAR THE SRS COMPONENTS OR
THE SRS WIRING, REFER TO THE SRS ON-VEHICLE
SERVICE INFORMATION. FAILURE TO FOLLOW
CAUTIONS COULD RESULT IN POSSIBLE AIR BAG
DEPLOYMENT, PERSONAL INJURY, OR
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS.
CAUTION: Always use the correct fastener in the
ONLY the exact part number for that application.
ISUZU will call out those fasteners that require a
replacement after removal. ISUZU will also call out
the fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do not
use supplemental coatings (paints, greases, or other 871RW001
corrosion inhibitors) on threaded fasteners or Service compressors are supplied with either the control
fastener joint interfaces. Generally, such coatings switches assembled in the rear head or a plug may be
adversely affect the fastener torque and the joint found where a control switch is required. If the service
clamping force, and may damage the fastener. When compressor requires control switches, the plug may be
you install fasteners, use the correct tightening removed from the appropriate rear head switch cavity of
sequence and specifications. Following these the replaced compressor and assembled as prescribed in
instructions can help you avoid damage to parts and this manual.
systems. When servicing the compressor, keep dirt or foreign
material from getting on or into the compressor parts and
General Description system. Clean tools and a clean work area are important
The HD6/HT6 Automotive Conditioning Compressor and for proper service. The compressor connections and the
Clutch Assembly is a light weight, six cylinder axial design outside of the compressor should be cleaned before any
consisting of three double ended pistons and weighs “on vehicle” repairs, or before removal of the compressor.
5.8 kg (12.7 lbs.) The parts must be kept clean at all times and any parts to
Although this compressor is the same for all vehicle be reassembled should be cleaned with solvent, and
applications, there are differences in installations, dried with dry air. When necessary to use a cloth on any
mounting brackets, pulleys, torque cushions and part, it should be of a non-lint producing type
switches, none of which will affect the following overhaul
procedures.
871RW002
Legend (6) Shaft Seal Parts

(1) Clutch Driver (7) Pump Assembly
(2) Rotor Bearing Retainer (8) High Pressure Relief Valve
(3) Pulley Rotor and Bearing Assembly (9) Shipping Cap
(4) Clutch Coil Assembly (10) Special 134a Suction Port
(5) Connector (11) Special 134a Discharge Port
The operations described below are based on bench

overhaul with the compressor removed from the vehicle,
except as noted. They have been prepared in order of
accessibility of the components. When a compressor is
removed from the vehicle for servicing, the amount of
PAG lubricant remaining in the compressor should be
drained, measured and recorded. This PAG lubricant
should then be discarded and an equal amount of new
PAG lubricant added to the compressor.
The service compressor is shipped without PAG oil.
When service procedures require, use only Isuzu
approved PAG oil.
Metric Thread Size Information

Compressor to mounting bracket bolts (Front) Compressor shaft
M10 × 1.5 – 6H M9 × 1.25 – 6H
Compressor to mounting bracket bolts (Rear) Internal hub-clutch drive assembly
M8 × 1.25 – 6H M22 × 1.5 – 6H
Suction-discharge port screw
M10 × 1.5 – 6H
Compressor Clutch Plate and Hub Assembly

Removal 2. Be sure the frictional surface of the clutch plate and
the clutch rotor (2) are clean before installing the
1. Clamp the holding fixture J-33026 in a vise and attach clutch plate and hub assembly (1).
compressor to holding fixture with thumb screws 3. Align the shaft key (4) with the shaft keyway (3) and
J-33026-1. place the clutch plate and the hub assembly onto the
2. With center screw forcing tip in place to thrust against compressor shaft.
the end of the shaft, thread the Clutch Plate and Hub
Assembly Installer-Remover J-33013-B into the hub.
Hold the body of the remover with a wrench and turn
the center screw into the remover body to remove the
clutch plate and hub assembly (1).
CAUTION: Do not drive or pound on the clutch hub
or shaft. Internal damage to compressor may result.
The forcing tip on J-33013-B remover-installer center
screw must be flat or the end of the shaft/axial plate
assembly will be damaged.
871RW003
4. Remove the forcing tip on J-33013-B clutch plate and

hub assembly installer-remover center screw and
reverse the body direction on the center screw, as
shown in Figure.
5. Install the clutch plate and hub installer-remover
J-33013-B with bearing as shown in Figure.
The body of the J-33013-B installer-remover should
be backed off sufficiently to allow the center screw to
be threaded onto the end of the compressor shaft.
901RW001
6. Hold the center screw with a wrench. Tighten the hex
3. Remove the shaft key and retain for reassembly. portion of the installer-remover J-33013-B body to
press the hub onto the shaft. Tighten the body
Installation several turns, remove the installer and check to see
that the shaft key is still in place in the keyway
1. Install the shaft key into the hub key groove. Allow the before installing the clutch plate and hub
key to project approximately 3.2 mm (1/8 in) out of assembly to its finial position. The air gap (2)
the keyway. The shaft key is curved slightly to provide between frictional surfaces of the clutch plate and
an interference fit in the hub key groove. clutch rotor should be 0.50–0.76 mm (.020–.030 in).
CAUTION: If the center screw is threaded fully onto
the end of the compressor shaft. or if the body of the
installer is held and the center screw is rotated, the 7. Remove installer J-33013-B, check for proper
key will wedge and will break the clutch hub. positioning of the shaft key (even or slightly above the
clutch hub).
8. Spin the pulley rotor by hand to see that the rotor is not
rubbing the clutch drive plate.
901RW002
Compressor Clutch Rotor and/or Bearing

Removal
1. Remove the clutch plate and hub assembly as
described previously.
2. Remove rotor (1) and bearing assembly retaining ring
(2), using snap ring pliers.
871RW007
Installation
1. With the compressor mounted to the J-34992 holding
fixture, position the rotor and bearing assembly on the
front head.
901RW003
3. Install pulley rotor and bearing puller guide J-33023-A 2. Position the J-33017 pulley, rotor and bearing installer
to the front head and install J-41552 pulley rotor and and J-33023-A puller pilot directly over the inner race
bearing puller down into the inner circle of slots (1) in of the bearing.
the rotor. Turn the J-41552 puller clockwise in the
slots in the rotor.
4. Hold the J-41552 puller in place and tighten the puller
screw against the puller guide to remove the pulley
rotor and bearing assembly.
3. Position puller crossbar J-8433-1 on the puller pilot 5. Install rotor and bearing assembly retainer ring, using
J-33023-A and assemble the two J-33026 through snap ring pliers .
bolts and washers through the puller bar slots and 6. Reinstall clutch plate and hub assembly as described
thread them into the J-33026 holding fixture. The previously.
thread of the through bolts should engage the full
thickness of the holding fixture.
4. Tighten the center screw in the J-8433-1 puller
crossbar to force the pulley rotor (1) and bearing
assembly onto the compressor front head. Should
the J-33017 pulley rotor and bearing installer slip off
direct in-line contact with the inner race of the bearing,
loosen the J- 8433-1 center forcing screw and realign
the installer and pilot so that the J-33017 installer will
properly clear the front head.
901RW005
Compressor Clutch Coil

Removal
1. Perform Steps 1 through 4 of “Clutch Rotor and/or
Bearings” removal procedure. Mark clutch coil
terminal location (1) on compressor front head.
2. Install J-33023-A puller pilot on front head of
compressor. Also install J-8433-1 puller crossbar with
J-33025 puller legs as shown in figure.
3. Tighten J-8433-3 forcing screw against the puller pilot
to remove the clutch coil (2).
901RW006
Installation
1. Place the clutch coil assembly (1) on the front head
with the terminals positioned at the “marked” location.
2. Place the J-33024 clutch coil installer over the internal
opening of the clutch coil housing and align installer
with the compressor front head.
3. Center the J-8433-1 puller crossbar in the
counter-sunk center hole of the J-33024 clutch coil
installer. Install the J-33026 through bolts and
washers through the crossbar slots and thread them
into the holding fixture J-33026 to full fixture
thickness.
871RW004
D Stake size should be only one-half the area of the

punch tip and be only approximately 0.28–0.35 mm
(.010–.015 in) deep.
901RW007
4. Turn the center forcing screw of J-8433-1 puller

crossbar to force the clutch coil onto the front head.
Be sure clutch coil and J-33024 installer stay “in-line”
during installation.
5. When coil is fully seated on the front head, use a 1/8 in
diameter drift punch (2) and stake the front head at
three places 120 degrees apart, to ensure clutch coil
(3) remains in position.
871RW005
Legend
(1) Stake Front Head 0.28–0.35 mm Deep
(0.10–015 in)
(2) Clutch Coil Housing
(3) Front Head Surface
6. Install rotor and bearing assembly and the clutch

plate and hub assembly as described previously.
Compressor Shaft Seal

Service Precaution Seal Leak Detection
When replacing the shaft seal assembly, pressure relief A shaft seal should not be changed because of small
valve or control switches, it will be necessary to recover amounts of oil found on an adjacent surface but only after
the refrigerant. Other than clutch repair procedures, the actual refrigerant leakage is found using an approved
same holds true for any disassembly of the compressor. leak detector.
A clean workbench covered with a sheet of clean paper, CAUTION: Handling and care of seal protector is
and a place (clean trays, etc) for all parts being removed important. If seal protector is nicked or the bottom
and replaced is important, as is the use of proper clean flared, the new seal may be damaged during
service tools. installation.
CAUTION: Any attempt to use makeshift or
inadequate service tools or equipment may result in
damage and/or improper compressor operation. Removal
All parts required for servicing the internal compressor 1. Recover the refrigerant using Refrigerant Recovery
are protected by a preservative process and packaged in System.
a manner which will eliminate the necessity of cleaning, 2. Loosen and reposition compressor in mounting
washing or flushing of the parts. The parts can be used in brackets, if necessary.
the internal assembly just as they are removed from the
service package. Seals and protective packaging 3. Remove clutch plate and hub assembly from
should be left intact until just prior to installation. compressor as described previously.
If the compressor rear head, front head or cylinder and 4. Remove the shaft seal retainer ring, using snap ring
shaft assembly is to be serviced or replaced, the oil in the pliers.
compressor must be drained, measured, recorded and 5. Thoroughly clean inside of compressor neck area
replaced. surrounding the shaft, the exposed portion of the
seal, the retainer ring groove and the shaft itself. Any
dirt or foreign material getting into compressor may
cause damage.
6. Fully engage the knurled tangs of Seal Remover-
Installer J-23128-A into the recessed portion of the
Seal (1) by turning the handle clockwise. Remove the
Seal from the compressor with a rotary-pulling
motion.
Discard the seal. The handle must be hand-tightened
securely. Do not use a wrench or pliers.
871RW006
Legend
(1) Suction Port
(2) Discharge Port
(3) Mounting Boss
(4) Mounting Boss
(5) Pressure Relief Valve
(6) Mounting Boss
901RW008
7. Remove and discard the seal seat O-ring (2) from the 2. Insert the O-ring installer J-33011 into the
compressor neck using O-ring remover J-9553-01. compressor neck until the installer “bottoms”. Lower
the moveable slide of the O-ring installer to release
the O-ring into the seal O-ring lower groove (The
compressor neck top groove is for the shaft seal
retainer ring.) Rotate the installer to seat the O-ring
and remove the installer.
3. Dip the new seal in clean 525 viscosity refrigerant oil
and assemble seal to Seal Installer J-23128-A, by
turning handle clockwise. The stamped steel case
side of the lip seal must be engaged with knurled
tangs of installer so that flared-out side of lip seal is
facing and installed towards the compressor. Install
seal protector J-34614, in the seal lip and place over
the compressor shaft, and push the seal in place with
a rotary motion or place the seal protector J-34614
over end of compressor shaft, and slide the new seal
onto the shaft with a rotary motion until it stops. Take
care not to dislodge the O-ring. Be sure the seal (2)
makes good contact with the O-ring. Disengage the
installer from the seal and remove the installer
J-23128-A and the seal protector J-34614.
901RW009
8. Recheck the shaft and inside of the compressor neck CAUTION: Handling and care of seal protector is
for dirt or foreign material and be sure these areas are important. If seal protector is nicked or the bottom
perfectly clean before installing new parts. flared, the new seal may be damaged during
installation.
Cleaning
Thoroughly clean O-ring seal groove in front head.
CAUTION: Seals should not be re-used. Always use
a new specification service seal on rebuild. Be sure
that the seal to be installed is not scratched or
damaged in anyway. Make sure that the seal seat and
seal are free of lint and dirt that could damage the
seal surface or prevent sealing.
Installation
1. Dip the new seal seat O-ring (1) in clean 525 viscosity
refrigerant oil and assemble onto O-ring installer
J-33011.
901RW011
4. Install the new seal retainer ring with its flat side
against the Seal, using Snap-Ring Pliers. Use the
sleeve from O-ring installer J-33011 to press in on the
seal retainer ring so that it snaps into its groove.
5. To leak test, install compressor leak test fixture
J-39893 on rear head of compressor and connect
gage charging lines and Refrigerant Recovery
System. Pressurize suction and high-side of
compressor with R-134a Refrigerant. Temporarily
install (M9 × 1.25 thread on shaft) nut and, with the
compressor in horizontal position, rotate the
compressor shaft in normal direction of rotation
several times by hand. Leak test the seal area and
correct and leak found. Recover the refrigerant.
Remove shaft nut.
901RW010
6. Remove any excess oil resulting from installing the 8. Reinstall compressor belt and tighten bracket.
new seal parts from the shaft and inside the 9. Evacuate and charge the refrigerant system.
compressor neck.
7. Install the clutch plate and hub assembly as
described previously.
Compressor Pressure Relief Valve

Removal 2. Lubricate O-ring of new pressure relief valve and
O-ring assembly with new 525 viscosity refrigerant
1. Recover the refrigerant using Refrigerant Recovery oil. Install new valve and torque in place, 9.0 N·m
System. (6.1 ft lbs)
2. Remove old pressure relief valve. 3. Evacuate and recharge the system.
4. Leak test system.
Installation
1. Clean valve seat area on rear head.
Compressor Oil
Compressor Oil Check 7. Install the compressor, then evacuate, charge and
perform the oil return operation.
The oil used to lubricate the compressor is circulating with
the refrigerant. 8. Check system operation.
Whenever replacing any component of the system or a
large amount of gas leakage occurs, add oil to maintain
When it is impossible to preform oil return operation,
the original amount of oil.
the compressor oil should be checked in the
(Oil Capacity) following order:
Capacity total in system 150 cc (5.0 fl.oz) 1. Discharge and recover refrigerant and remove the
compressor.
Compressor (Service 150 cc (5.0 fl.oz)
2. Drain the compressor oil and measure the extracted
parts) charging amount
oil with a measuring cylinder.
3. Check the oil for contamination.
4. If more than 90 cc (3.0 fl. oz.) of oil is extracted from
Checking and Adjusting Oil Quantity the compressor, supply the same amount of oil to the
for Used Compressor compressor to be installed. If the amount of oil
extracted is less than 90 cc (3.0 fl. oz.), recheck the
1. Perform oil return operation. Refer to Oil Return compressor oil in the following order:
Operation in this section.
5. Supply 90 cc (3.0 fl. oz.) of oil to the compressor and
2. Discharge and recover refrigerant and remove the install it onto the vehicle.
compressor.
6. Evacuate and recharge with the proper amount of
3. Drain the compressor oil and measure the extracted refrigerant.
7. Perform the oil return operation.
4. If the amount of oil drained is much less than 90 cc
8. Remove the compressor and recheck the amount of
(3.0 fl. oz.), some refrigerant may have leaked out.
oil.
Conduct a leak tests on the connections of each
system, and if necessary, repair or replace faulty 9. Adjust the compressor oil, if necessary.
parts.
(Collected Amount) (Charging Amount)
5. Check the compressor oil contamination. (Refer to
Contamination of Compressor Oil in this section.) more than 90 cc (3.0 same as collected
fl.oz) amount
6. Adjust the oil level following the next procedure
below. less than 90 cc (3.0 fl.oz) 90 cc (3.0 fl.oz)
(Collected Amount) (Charging Amount)
more than 90 cc (3.0 same as collected
fl.oz) amount
Checking and Adjusting for
less than 90 cc (3.0 fl.oz) 90 cc (3.0 fl.oz)
Compressor Replacement
The oil is not charged in compressor (service parts). So it
is necessary to charge the proper amount of oil to the new
compressor.
1. Perform oil return operation. (Component parts to be (Amount of Oil)
2. Discharge and recover the refrigerant and remove the installed)
compressor.
Evaporator 50 cc (1.7 fl. oz.)
oil. Condenser 30 cc (1.0 fl. oz.)
4. Check the compressor oil for contamination. Receiver/dryer 30 cc (1.0 fl. oz.)
5. Adjust the oil level as required. Refrigerant line (one 10 cc (0.3 fl. oz.)
piece)
(Amount of oil drained (Charging amount of oil
from used compressor) to new compressor)
more than 90 cc (3.0 same as drained amount
fl.oz) Compressor Leak Testing (External
less than 90 cc (3.0 fl.oz) 90 cc (3.0 fl.oz) and Internal)
Bench-Check Procedure
6. Evacuate, charge and perform the oil return
operation. 1. Install test plate J-39893 on rear head of compressor.
7. Check the system operation. 2. Using Refrigerant Recovery System, attach center
hose of manifold gage set on charging station to a
refrigerant drum standing in an upright drum.
Contamination of Compressor Oil 3. Connect charging station high and low pressure lines
Unlike engine oil, no cleaning agent is added to the to corresponding fittings on test plate J-39893.
compressor oil. Even if the compressor runs for a long Suction port (low-side) of compressor has large
period of time (approximately one season), the oil never internal opening. Discharge port (high-side) has
becomes contaminated as long as there is nothing wrong smaller internal opening into compressor and deeper
with the compressor or its method of use. recess.
Inspect the extracted oil for any of the following 4. Open low pressure control, high pressure control and
conditions: refrigerant control on charging station to allow
D The capacity of the oil has increased. refrigerant vapor to flow into compressor.
D The oil has changed to red. 5. Using a leak detector, check for leaks at pressure
relief valve, rear head switch location, compressor
D Foreign substances, metal powder, etc., are present front and rear head seals, center cylinder seal,
in the oil. through bolt head gaskets and compressor shaft
If any of these conditions exists, the compressor oil seal. After checking, shut off low pressure control and
is contaminated. Whenever contaminated high-pressure control on charging station.
compressor oil is discovered, the receiver/drier must 6. If an external leak is present, perform the necessary
be replaced. corrective measures and recheck for leaks to make
certain the leak has been connected.
Oil Return Operation 7. Recover the refrigerant.
There is close affinity between the oil and the refrigerant. 8. Disconnect both hoses from the test plate J-39893.
During normal operation, part of the oil recirculates with 9. Add 90 ml (3 oz.) new PAG lubricant to the
the refrigerant in the system. When checking the amount compressor assembly. Rotate the complete
of oil in the system, or replacing any component of the compressor assembly (not the crankshaft or drive
system, the compressor must be run in advance for oil plate hub) slowly several turns to distribute oil to all
return operation. The procedure is as follows: cylinder and piston areas.
1. Open all the doors and the engine hood. 10. Install a M9 × 1.25 threaded nut on the compressor
2. Start the engine and air conditioning switch to “ON” crankshaft if the drive plate and clutch assembly are
and set the fan control knob at its highest position. not installed.
3. Run the compressor for more than 20 minutes 11. Using a box-end wrench or socket and handle, rotate
between 800 and 1,000 rpm in order to operate the the compressor crankshaft or clutch drive plate on the
system. crankshaft several turns to insure piston assembly to
4. Stop the engine. cylinder wall lubrication.
12. Using Refrigerant Recovery System, connect the
charging station high-pressure line to the test plate
Replacement of Component Parts J-39893 high-side connector.
When replacing the system component parts, supply the 13. Using Refrigerant Recovery System, connect the
following amount of oil to the component parts to be charging station low-pressure line to the low pressure
installed. port of the test plate J-39893. Oil will drain out of the
compressor suction port if the compressor is
positioned with the suction port downward.
14. Attach the compressor to the J-34992 holding fixture
and mount the compressor in a vise so that the
compressor will be in a horizontal position and the
shaft can be turned with a wrench.
15. Using a wrench, rotate the compressor crankshaft or
drive plate hub ten complete revolutions at a speed of
approximately one-revolution per second turning the
compressor at less than one-revolution per second
can result in a lower pump-up pressure and disqualify
a good pumping compressor.
16. Observe the reading on high-pressure gauge at the
completion of the tenth revolution of the compressor.
The pressure reading for a good pumping
compressor should be 690 kPa (100 psi) or above. A
pressure reading of less than 620 kPa (90 psi) would
indicate one or more suction and/or discharge valves
leaking an internal leak, or an inoperative valve, and
the refrigerant must be recovered and the
compressor disassembled and checked for cause of
leak. Repair as needed, reassemble and repeat the
pump-up test. Externally leak test.
17. When the pressure pump-up test is completed,
recover the refrigerant from the high-side and remove
the test plate J-39893.
18. Tilt the compressor so that the compressor suction
and discharge ports are down. Drain the PAG
lubricant from the compressor.
19. Allow the compressor to drain for 10 minutes, then
refill with the proper amount of PAG lubricant, per oil
balance procedure described previously. The PAG
lubricant may be poured into the suction port. If
further assembly or processing is required, a shipping
plate or test plate J-39893 should be installed to keep
out air, dirt and moisture until the compressor is
installed.
Special Tools
TOOL NO. TOOL NO.
ILLUSTRATION ILLUSTRATION
TOOL NAME TOOL NAME
J-33013-B
J-8433-3
Hub and Clutch Drive
Forcing Screw
Plate Asm. remover
J-33026 J-33025
Compressor Holding Clutch Coil Installer
Fixture Adapter
J-33024
J-33023-A
Clutch Coil Installer
Puller Pilot
Adapter
J-23128-A
J-41552
Seal Seat Remover and
Pulley Puller
Installer
J-33017
J-9553-01
Pulley and Bearing
O-Ring Remover
Assembly Installer
J-8433-1 J-33011
Puller Bar O-Ring Installer
TOOL NO.
ILLUSTRATION
TOOL NAME
J-34614
Shaft Seal Protector
J-39893
Pressure Testing
Connector
Automatic Air Conditioning System

General Description off the compressor and switch the blow port as well as
switching between the fresh air intake and interior air
Using a variety of sensors, this automatic heater and air circulation.
conditioner accurately senses outside air temperature, Resetting the automatic function allows you to switch to
solar radiation quantity, evaporator’s blowing the manual control mode.
temperature, and interior temperature, then enters these The self-diagnoisis function of the automatic heater and
data to the automatic heater/air conditioner control unit air conditioner control unit (with the built–in
(equipped with the built-in micro-computer). The data micro–computer) allows the unit to access and diagnose
provided to the control unit enables to automatically a failed part easier and quicker.
control blow temperature and blow air quantity, turn on or
Full Automatic Air Conditioner Parts Configuration
865RY00008
Legend (7) Max – High Relay

(1) Sun Sensor (8) Automatic Air Conditioner Control Unit
(2) Lower Center Vent Box (9) In Car Sensor
(3) Evaporator Assembly (10) Heater Unit
(4) Duct Sensor (11) Mode Actuator
(5) Intake Actuator (12) Mix Actuator
(6) Blower Unit
852RY00002
Legend (7) Condenser Assembly

(1) Liquid Line (High Pressure Pipe) (8) Drive Belt
(2) O – Ring (9) Compressor
(3) Discharge Line (High Pressure Hose) (10) Drain Hose
(4) Pressure Switch (11) Suction Line (Low-Pressure Hose)
(5) Receiver Drier (12) Evaporator Assembly
(6) Ambient Sensor (13) A/C Switch
Circuit Diagram
6VE1 Engine
D08RY00109
D08RY00110
D08RY00155
D08RY00147
D08RY00148
Functions and Features the system.

Self-diagnosis function
Automatic interior temperature control
The self-diagnosis function turned on from the panel
This function enables to maintain the interior switch makes your troubleshooting easier (for detail
temperature at the level specified from the of this function, refer to the section titled
temperature control switch despite of changes in “Self-Diagnosis”).
factors such as vehicle speeds, outside air
temperature and number of passengers.
Maximum cooling and heating function
You can select FC (Full cool, namely maximum cooling
temperature) or FH (Full heat, maximum heating
temperature) from the temperature control lever.
Automatic air flow control
Air flow is automatically and consecutively fine tuned
according to the specified interior temperature and
changes in aperture of the heater unit mix door.
Mode (blow port) control
This function automatically selects either one of the
VENT, BI-LEVEL, FOOT or DEF mode for the blow
port according to changes of temperature on the
blow port. Using the mode switch allows you to
select a desired blow port manually.
Intake (switching between the fresh air intake and
circulation of interior air) control
The intake (switching between fresh air intake and
circulation of interior air) mode automatically selects
either FRESH (fresh air intake), MIX or RECIRC
(interior air circulation) according to changes of the
blow port temperature. Using the intake switch
allows you to select a desired intake port manually
(in the manual operation, FRESH and RECIRC
modes alone are available). Pressing the DEF
(defrost) mode switch selects the FRESH (fresh air
intake).
Cooler start-up timing control
This function is used for maintaining the air flow at
“LOW” level until the evaporator is sufficiently
cooled down. It is intended to prevent a large
volume of hot air being blowing into inside of a
vehicle when the cooler is turned on in hot summer
season.
Heater start-up timing control
This function is used for maintained the air flow at
“LOW” level and also for maintaining the defrost
mode until temperature of coolant in the heater core
is sufficiently heated. It is intended to prevent a
large volume of cool air being blown into inside of a
vehicle when the heater is turned on in cold winter
season.
Solar radiation quantity offset control
The photodiode on the sun sensor determines solar
radiation quantity accurately to offset interior
temperature quickly.
Switch position storing function
This function is used for storing switch positions being
selected in the immediately preceding operation,
namely the last time the ignition has been turned off.
It simplifies the setup procedures when restarting
Automatic Air Conditioner Block Diagram
F01RY00006
Control Panel Layout
865RY00024
Legend (5) Intake Switch

(1) Auto Switch (6) Fan Switch
(2) Mode Switch (7) Air Conditioning Switch
(3) DEF/FOOT Switch (8) Temperature Control Knob
(4) DEF Switch
Air Control Functions
C01RY00004
Legend (7) FOOT Door

(1) Interior Air Intake (8) Sub Air Mix Door
(2) Fresh Air Intake (9) Heater Unit
(3) Evaporator Core (10) Heater Core
(4) Air Mix Door (11) Evaporator Unit
(5) DEF Door (12) Blower Unit
(6) VENT Door
Operation and Functions of Control Panel Switches

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

D The Auto LED maintains unaffected. 1. Sets the fan to the specified mode.
D Currently selected intake port is indicated. 2. Even when the fan switch is turned off, status display
for the Mode, Intake is maintained.
Temperature Control Knob

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

*2: The ON mode is available only when ON is selected
for the fan as well as for the cold outside air
ON/OFF selection.
*3: When the MAX control is selected from the DEF
mode, this DEF mode shall be maintained.
Indication
D As long as the MAX control is selected, the
immediately preceding indication shall be maintained
for the AUTO.
D Status display is provided for others.
Air Conditioning Switch

Pressing this switch turns on or off the A/C (air
conditioning) control. (The compressor remains turned
off if the fan is turned off and also the compressor has
been turned off because of the given outside air
temperature level.)
Indication
1. The A/C LED remains turned on even if the
compressor has been turned off because of the given
outside air temperature level. In this case, however,
the AUTO or DEF switch must be turned on and the
A/C ON mode must also be turned on (by the MAX/C
mode). 865RY00020
2. Pressing the A/C switch from the above state (1) Legend
turns off the A/C LED. (1) In Car Sensor
(2) Automatic Air Conditioner Control Unit
Overview of Construction, Movement
and Control of Major Parts of Ambient Sensor
Automatic Air Conditioner System This sensor is used for detecting temperature outside the
vehicle. It converts a given outside air temperature into a
Automatic Heater/Air Conditioner Control resistance value before entering the data to the automatic
Unit heater/air conditioner control unit.
Thermal effects from the condenser and radiator during
Equipped with the built-in micro-computer, this control idling after a run can be measured and offset the
unit operates on signals from sensors and input signals automatic amplifier.
from switches to offer total control of the blower fan, and This sensor is provided on the side plate situated at upper
actuators used for the mode door, intake door and air mix right side of the condenser.
door.
Its self-diagnosis function enables quicker access to a
failed part and its more accurate troubleshooting.
In Car Sensor
It is a sensor used for detecting room temperature of a
vehicle. This sensor converts a given room temperature
into a resistance value before entering the data to the
automatic heater/air conditioner control unit.
This in car sensor unites the power driven aspirator and
the motor fan so that a small amount of room air may be
constantly fed to the sensor.
This sensor is provided on the control panel.
845RY00001
Legend
(1) Ambient Sensor
(2) Condenser Assembly
Duct Sensor Sun Sensor
The duct sensor is the sensor to detect temperature It is a photodiode used for detecting quantity of solar
change of the side of evaporator blower coming by fresh radiation. This sensor converts the offset signal
recirculation of intake door or “on” “off” of compressor. generated by changes in the interior temperature (which
The temperature is converted to resistant rate. results from fluctuations in solar radiation) into
And it works as thermostat to control to prevent freezing photoelectric current to enter into the automatic heater/air
of evaporator. conditioner control unit.
This sensor is installed in the upper case of evaporator. This sensor is provided at top of the defroster grill.
860RY00007 826RY00012
Legend Legend
(1) Duct Sensor (1) Sun Sensor
(2) Electro Thermo
(3) Evaporator
Power Transistor
Receiving base current from the automatic heater/air
conditioner control unit, the power transistor implements
stage–less speed change of the blower fan motor. This
transistor is provided on the evaporator.
874RY00011
Legend
(2) Power Transistor
Max Hi Relay Actuator
This relay turned on or off by the signal from the automatic The actuators are power driven type containing a small
heater/air conditioner control unit. As the Max Hi relay is motor. Receiving output current from the automatic
turned on, supply voltage is directly fed to the blower fan heater/air conditioner control unit, actuators drive the
motor to select the Max Hi mode. heater and blower unit mode doors.
Actuators consist of the mode actuator used for switching
the mode (blow port selection), the mix actuator used for
changing aperture of the air mix door, the intake actuator
used for switching the intake mode(fresh air/interior air)
and the cold air bypassing actuator.
873RY00005
Legend
(1) Blower Unit
(2) Max High Relay
860RY00006
Legend
(1) Mix Actuator
(2) Intake Actuator
(3) Blower Unit
(4) Mode Actuator
(5) Heater Unit
The actuator changes the motor speed using the gear Movement of Mix Actuator
and drives each door rotating the output axis united with Position of the air mix door is determined by the controller
the sliding contact. on the automatic heater/air conditioner control unit.
As the heat or cool side of the controller is grounded, the
transistor on the driver is activated and, thus, the motor
rotation is turned on. The sliding contact connected to the
motor sends the position detection signal from the
potentiometer to the automatic heater/air conditioner
control unit. As the set temperature and interior
temperature are balanced, the controller returns to the
neutral and the motor rotation is stopped.
I-45 Rotation Remarks
direction
(+) side (-) side
8 6 Clockwise Full heat side
6 8 Counter Full cool side
clockwise
860RW026
Legend
(1) Output Axis
(2) Motor
(3) Printed Circuit Board
(4) Sliding Contact
The mode and mix actuators are common actuators with

the built–in potentiometer. For the intake actuator, the
contact switch type is selected.
The potentiometer is a register assembled to the printed
circuit board of the mix and mode actuators. It detects the
air mix door position specified by rotation of the output
axis as a ratio of the variable terminal (VM) voltage
against the reference voltage (VDD: 5V), then signals the
value to the automatic heater/air conditioner control unit.
C01RX005
C01RX016
Movement of Mode Actuator Movement of Intake Actuator
As target position of the mode door is decided on the The controller on the automatic heater/air conditioner
controller of the control unit, the control unit reads the control unit selects an intake mode to be used.
position detection signal from the actuator to select the As the Terminal No.5 I-49 is grounded via the sliding
clockwise or counter clockwise motor rotation direction. contact on the terminal plate, the transistor on the driver is
Grounding the controller VENT or DEF side after the activated, thus turning on the motor rotation. Then,
direction selection activates the transistor on the driver, accompanying move of the motor, the sliding contact
thus turning on the motor rotation. Accompanying the rotates until grounding of the Terminal No.5 I-49 is
motor rotation, the sliding contact rotates, too. When the removed, thus stopping the motor.
target position is reached, the controller on the control
unit returns to the neutral and the motor stops. Grounding ter- Rotation direc- Remarks
minal tion
Conduction pin Rotation Remarks No.5 I-49 Clockwise RE-CIRCULA-
direction TION→MIX→F
(+) side (-) side
RESH
5 1 Clockwise VENT to DEF
direction
1 5 Counter DEF to VENT
clockwise direction
C01RX006
Overview of Automatic Control of

Automatic Air Conditioner
The full automatic heater and air conditioner on this
vehicle has the following features:
D Interior temperature control.
D Air flow control.
D Mode (blow port) control.
D Intake (switching between fresh air and interior air)
control.
D Heater start timing control.
C01RX017
D Cooler start timing control.
D Evaporator anti-freeze control.
Interior Temperature Control Air Flow Control
The automatic heater/air conditioner control unit operates In the Auto Mode
on the setup temperature signal from the temperature
control switch and other sensor signals to derive the total D The automatic heater/air conditioner control unit
operates on the setup temperature signal and other
signal. Then, the control unit compares this signal
sensor signals to derive the total signal. Then, the
against the signal from the potentiometer to determine
control unit adjusts base potential of the power
rotation direction of the mix actuator. The mix actuator transistor to match it to the voltage pattern of the
moves the air mix door to the aperture specified by the target fan so that stage-less fan speed control can be
total signal so that the specified interior temperature is achieved.
achieved. When solar radiation quantity is detected in the VENT
If the compressor is turned off in the A/C (air conditioning) or B/L mode, the control unit increases the minimum
mode, aperture of the air mix door is offset according to fan voltage to offset.
the outside air temperature or the specified interior
When FH or FC is selected from the temperature
temperature. This function removes the difference in the
control switch, air flow is accordingly fixed to MAX HI or
blowing temperature in this state and that of when the AUTO HI.
compressor is turned on.
When FH or FC is selected for the setup temperature, the In the Manual Mode
air mix door is accordingly fixed to the Full Heat or Full D Air flow specified from the fan switch is entered to the
Cool mode. automatic heater/air conditioner control unit as the
When the VENT mode is selected, aperture of the air mix manual signal. The signal modifies the air flow to the
door is controlled so that excessively heated air may not level specified from the fan switch so that the required
be blown from the VENT blow port. fan voltage is attained.
C01RY00011 C01RY00008
Mode (Blow Port) Control Intake (Fresh air/interior air switching)
The automatic heater/air conditioner control unit operates Control
on the setup temperature from the control switch, and In the Full Auto mode, the automatic heater/air
temperature and solar radiation quantify from the sensors conditioner control unit operates on the setup
to determine the total mode control signal. According to temperature signal and other sensor input signals to
the pattern specified by this signal, the control unit selects derive the total signal. According to the pattern specified
either one of the VENT, BI-LEVEL, FOOT or DEF/FOOT by this signal, the control unit provides the intake control.
mode. When the fan is turned off or the A/C (air conditioning) is
The mode actuator determines the rotation direction turned off, the intake is fixed to the FRESH mode.
comparing the target position against the current position When FC or FH is selected from the control switch, the
being determined by the position detection signal. intake mode is accordingly fixed to the RECIRC or
When FH or FC is selected for the temperature from the FRESH.
temperature control switch, mode is accordingly fixed to In the Manual Operation
the VENT or FOOT.
D In the manual operation of the mode switch, you can D Pressing the FRESH (fresh air intake) or the RECIRC
select a desired blow port mode pressing the (room air circulation) accordingly selects the FRESH
corresponding mode switch. or RECIRC mode.
D Operating the DEF mode switch selects the DEF for When the DEF Mode Switch is depressed
the blow port mode. D The intake mode is fixed to the FRESH. When the
MANU REC is selected, however, the mode is fixed
the RECIRC.
When the Mode Switch is depressed
D If the automatic intake control is selected, the intake is
fixed to the currently selected mode.
C01RY00009
C01RY00012
Compressor Control
In the automatic control mode, the automatic heater/air
conditioner control unit turns on or off the compressor
with the evaporator anti–freeze mechanism using the
evaporation sensor. And, when outside air is detected to
be low through the outside air temperature sensor signal,
the control unit turns off the compressor using the
compressor control function.
Manual Control
D In the automatic control mode, pressing the A/C (air
conditioning) switch turns off the compressor.
D Pressing the DEF mode switch automatically turns on
the compressor.
840RY00018
Cooling Start Timing Control

When the automatic heater/air conditioner is started,
cooling is turned on under following conditions.
D The in car sensor is 86°F or more.
D The temperature setting signal and the signals from
each sensor meet the specified condition.
The blower fan speed is set to “LO” for maximum 7
seconds when cooling start conditions meet, and then, is
controlled to be lineally up to “MAX HI” by 5.32%/S.
C01RY00010
Heating Start Timing Control

When the automatic heater/air conditioner is started,
heating is turned on under following conditions.
D The detected temperature of thermo unit is 136°F or
less.
D The temperature setting signal and the total signal by
each sensor meet the condition of heating.
When the detected temperature by the coolant
temperature sensor is 136°F or less, the blower fan motor
is set to work at low speed and the “DEF” mode is
selected.
When the detected temperature by the coolant
temperature sensor is 77°F or more, the blow mode
changes automatic control. And the blower fan speed is
controlled to be lineally up from “LO” to “MAX HI”. C06RY00001
Troubleshooting
Troubleshooting, Its Overview and When implementing the troubleshooting, this
self-diagnosis function narrows the range to be searched
Procedures at the first step, then check relevant parts one by one
The full automatic heater and air conditioner equips with according to the “Checking Procedures by Failed
the “Self-Diagnosis Function” to check its major Location”. As for a location this function is unappreciable,
components. the system accurately determines characteristics of a
This function makes access to the sensors, actuators and given trouble and checks relevant parts according to the
blower fan motor system easier when checking them up “Checking Procedures by Failed Location”.
and, when a failed part is located, this function restores its The following illustrates basic troubleshooting flow.
original performance.
Basic Troubleshooting Flow
F01RX009
Auto Air Conditioner Control Unit Power Supply Diagnosis

This check is required because a trouble on the auto
amplifier (control unit) power supply circuit or grounding
circuit prevents accurate troubleshooting.
D08RY00138

Power source does not supply to — Refer to Chart A
auto air conditioner control unit.
Chart “A”: Check of Auto Amplifier Power Supply System

Step Action Value(s) Yes No
1 Is the fuse C–16 normal? Replace the
— Go to Step 2 fuse
3 Disconnect the auto A/C control unit connector I–32.
Is the battery voltage applied between the harness side
connector terminal No.I32–8 and the ground? Approx. 12V Go to Step 5 Go to Step 4
4 Repair an open circuit between the fuse C–16 and
terminal No.I32–8.
Is the action complete? — Go to Step 4 —
5 Is there continuity between the harness side connector
terminal No.I33–16 and the ground? — Go to Step 7 Go to Step 6
6 Repair an open circuit between terminal No.I33–16 and
the ground No.B–2.
7 Turn the lighting switch on.
connector terminal No.I32–10 and the ground? Approx. 12V Go to Step 9 Go to Step 8
8 Repair an open circuit between the lighting switch and
9 Turn the starter switch on.
connector terminal No.I32–7 and the ground? Approx. 12V — Go to Step 10
10 Repair an open circuit between the fuse C–20 and
Is the action complete? — Verify repair —
Performance and Movement checklist for

Automatic Air Conditioner Related Parts
Start the engine, and when the engine coolant reached
122°F check performance and movement of the related
parts according the following checklist.
Performance Check Using the Manual Switch

Checking Approach
No
No. Item Acceptance criteria
Condition Operation
Blowing Auto switch must be 1. Cold air shall be blown out.
temperature turned 1. Select FC for the 2. Hot air shall be blown out.
(check movement on(FAN–AUTOMODE setup temperature.
1 of air mix door) –AUTO) 2. Select FH for the
setup temperature.
→ Then, select the
MAX Control.
Airflow Set temperature to 1. Turn the fan knob 1. The fan shall be stopped, thus
volume(check 77°F. off. stopping air blow, too.
2 movement of the 2. Turn the fan knob 2. Airflow volume shall change from
mode door) from LOW to HI. LOW to HI.
Blowing Set temperature to Push the mode switch LED corresponding to each mode
temperature(chec 77°F.Set the fan knob to change the blow shall be turned on and the blow port
k movement of to HI. port mode sequentially mode shall be switched smoothly.
3
the mode door) from the VENT
through BI-LEVEL,
FOOT up to DEF.
The Set temperature to Turn the LED off using The LED indication shall be
interior/outside air 77°F. the interior/outside air switched from OFF to ON
switching mode switch (this introduces accompanying a change in air
(check movement the outside air intake blowing sound.
4 of intake door) mode). Then, the set
fan knob to HI and
press the
interior/outside switch
to turn on the LED.
Compressor Set the temperature to Push the “OFF” 1. As the fan knob is set to the Auto
64.4°F (FC). (Outside switch. position, the A/C switch LED
air temperature is 1. Push the Auto shall come on and the
5 32°F or above and compressor shall be turned on.
switch.
interior temperature at 2. Push the Air 2. As the A/C LED comes off, the
ordinary temperature.) Conditioner switch. compressor shall be turned off.
Check of Auto Function
Checking Approach
No
No. Item Acceptance criteria
Condition Operation
The LED shall come on.
Cold air shall be blown out.
The following LEDs shall come on:
Select FC for the D Blow port mode:
temperature. D Intake mode
D Fan speed:
MAX Hi
D A/C
The following phenomena
shall be recognized.
D Temperature of blown air: Cold air
FAN KNOB “AUTO” Change the
1 Auto function is changed to hot air.
MODE SW “AUTO” temperature
D Change in the air flow volume.
gradually starting
with 68°F up to D The blow port mode LED indication
86°F. changes in the following sequence:
Cold air shall be blown out. The

following LEDs shall come on.
Select FH for the
D Blow port mode:
temperature.
D Fan speed: Max
Hi.
Troubleshooting With Self-Diagnosis Function

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

1 1. Set the IG to the OFF position.
2. Apply 60W bulb light to the sun sensor.
3. Set the temperature setting lever on the automatic
heater/air conditioner panel to the center position
(77°F).
4. Set the fan switch on the same panel to the Auto
position.
2 While pushing both the Auto switch and the DEF switch
on the automatic heater/air conditioner panel, start the
engine.
Is the current trouble diagnosing function turned on
approximately in 10 seconds? — Go to Step 3 —
3 Does the A/C LED flash every 0.5 second interval? — Go to Step 4 Refer to *1.
4 Push the A/C switch once.
Does the A/C LED flash every 0.5 second interval? — Go to Step 5 Refer to *2.
5 Refer to *3 chart “Check of Output Equipment”. Repair or
replace the
Does each output equipment function normally
output
according to operation of the temperature setting
equipment or
level?
repair the
— Go to Step 6 harness
6 Push the DEF switch for 5 seconds consecutively or
turn on and off the IG.
*1Displaying the Current Trouble one in 0.5 second interval irrespective of presence or
Diagnosing Table absence of a trouble for a given item. When the display 9
items is completed, it is repeated with 3 seconds of
Start the engine while holding down both the Auto switch
interval in between. A failed item is indicated by flashing of
and the DEF switch on the control panel, and the table will
the LED that is repeated 3 times within 0.5 seconds. If a
appear in approximately 10 seconds to the indicator lamp
trouble is indicated, you can locate the failed section by
(LED) of the air conditioning switch. Result of the
knowing when in the total sequence it has been
diagnosis along the following 9 items will be shown one by
displayed.
F01RX010
Item for Current Trouble Diagnosis
F01RY00008
As shown above, display of result along nine items is past trouble diagnosis will appear on the indicator lamp
repeated with 3-second interval in between. (LED) of the air conditioning switch.
Note 1: When checking the sun sensor, apply sufficient Results of the diagnosis along the following five items are
light using a 60W bulb. Otherwise, it can be diagnosed as displayed one by one in 0.5 second interval irrespective of
failed. presence or absence of a trouble. A failed item is
Note 2: If the temperature setting lever is set on both ends indicated by flashing of the LED that is repeated 3 times
(one set to 64.4°F, blue scale = Full cool and the other to within 0.5 seconds. You can locate the failed section by
87.8°F, red scale = Full hot), they can be diagnosed as counting in what sequence it has been displayed.
failed. Past trouble code can be cleared by disconnecting one of
Note 3: Likewise, the fan switch can be diagnosed as the following sources for at least thirty (30) seconds.
failed if set on both ends. NOTE: To prevent system damage, the ignition key must
be “OFF” when disconnecting or reconnecting battery
*2Displaying the Past Trouble Diagnosing power.
Table
D The No.16 fuse (Room lamp, Clock)
The past trouble diagnosis displays only the items on
which trouble has recurred 16 times in the past. D The negative battery cable. (Disconnecting the
If you press the air conditioning switch once while the negative battery cable will result in the loss of other
current trouble diagnosis is taking place, display of the on-board memory data, such as preset radio tuning).
F01RX011
F01RY00007
*3Check of Output Equipment
F01RY00004
Inspection By Failed Location

Inspection of the Sensors
When the self-diagnosis function has determined that
trouble is present on the sensors, check them according
to the following flow chart.
F01RY00005
Chart 1: In Car Sensor
D08RY00174

1 Disconnect the in car sensor connector. (No.I-34)
Is performance of the sensor normal? (Refer to the Replace the
later section on “Individual Inspection”) — Go to Step 2 in car sensor
No.I33–1 and No.I34–3? — Go to Step 4 Go to Step 3
No.I34–3.
No.I33–11 and No.I34–4? — Go to Step 6 Go to Step 5
5 Replace the auto air conditioner control unit.
Chart 2: Ambient Sensor
D08RY00140

1 Disconnect ambient sensor connector. (No.C–86)
Replace the
Is performance of the ambient sensor normal? (Refer ambient
to the later section on “Individual inspection”) — Go to Step 2 sensor
2 Connect the ambient sensor connector. Refer to the
later section
Is resistance between the harness side connector
No.I33–2 and No.I33–11 normal? on “Individual
inspection” Go to Step 4 Go to Step 3
No.C86–1 or No.I33–11 and No.C86–2.
Chart 3: Sun Sensor
D08RY00139

1 Disconnect the sun sensor connector. (No.I–35)
Is performance of the sun sensor normal? (Refer to the Replace the
later section on individual inspection) — Go to Step 2 sun sensor.
terminal No.I33–3 and No.I35–2? — Go to Step 4 Go to Step 4
No.I35–2.
I35–1.
Inspection of the Intake Actuator System
D08RY00142

Does not work at all — Refer to Chart A
Control failure — Refer to Chart B
Chart A: Does Not Work At All

1 Is the fuse FL–1 normal? Replace the
3 Is the relay B–36 normal? Replace the
— Go to Step 4 relay
4 Turn on the ignition switch. (the engine is run.)
connector terminal No.I49–3 and ground? Approx 12V Go to Step 6 Go to Step 5
No.B36–4.
6 Is the battery voltage applied between the harness side
connector terminal No.I49–4 and ground? Approx 12V Go to Step 8 Go to Step 7
7 Replace the intake actuator motor.
terminal No.I32–11 and No.B49–4? — Go to Step 10 Go to Step 9
9 Repair an open circuit between No.I32–11 and I49–4.
Chart B: Failure on the Intake Control

1 Is the fuse No.C–20 normal? Replace the
2 Is the relay No.B–36 normal?
Replace the
3 Turn on the ignition switch. (the engine is run.)
Is the intake actuator stopped? — Go to Step 5 Go to Step 4
4 Replace or repair the auto air conditioner control unit.
No.I33–11.
No.I33–12.
I33-13.
12 Repair an open circuit between harness No.I49–2 and
No.I33–14.
13 1. Disconnect the intake actuator connector No.I49.
2. Is the battery voltage applied between harness side
connector terminal
No.I49–6 and ground?
— Go to Step 14 Go to Step 15
14 Replace or repair the intake actuator.
15 Replace or repair the air conditioner control unit.
Inspection of the Mix Actuator System
D08RY00145

Chart A: Does Not work At All

1 1. Turn on the ignition switch (the engine is run).
2. Disconnect the mix actuator connector (I–45).
3. Short-circuit the chassis harness side connector
terminal No.I45–3 and No.I45–7.
4. Using the temperature control lever, select FH for
the temperature.
Is the battery voltage applied on a regular interval basis
between the harness side connector terminal No.I45–6
(-) and No.I45–8 (+)? — Go to Step 3 Go to Step 2
— Varify repair —
3 Using the temperature control lever, select FC for the
temperature.
Is the battery voltage applied on a regular interval basis
between the harness side connector terminal No.I45–6
(+) and No.I45–8 (-)? — Go to Step 5 Go to Step 4
— Verify repair —
No.I45–6.
7
Is there continuity between the harness side connector
No.I45–8.
9 Replace the mix actuator.
Chart B: Mix Actuator Control Failure

1 Turn the ignition switch (the engine is run).
Dose the mix actuator fully stroke when FH and FC of
the temperature control lever? — Go to Step 3 Go to Step 2
2 Repair or replace the air mix door or the link unit.
Is the action complete? — Varify repair —
No.I33–11.
5 Is there continuity between harness side connector
No.I33–5.
terminal No.I45–2 and No.I33–15?
— Go to Step 9 Go to Step 8
No.I33–15.
9 Is sum of the voltage between the following chassis
harness side connector terminals approximately 5V?
No.I33–15 and No.I33–5, No.I33–5 and No.I33–11 — Go to Step 11 Go to Step 10
10 Replace the actuator.
Inspection of the Mode Actuator System
D08RY00146

Chart A: Does Not Work At All

2. Disconnect the mode actuator connector (B–69)
3. Select VENT pressing the mode actuator.
Is the battery voltage provided on a regular interval
between the harness side connector terminal
No.B69–1 (+) and No.B69–5 (-)? — Go to Step 3 Go to Step 2
Is the action complete? — Varify repair —
3 Turn on the DEF mode switch.
Is the battery voltage provided on a regular interval
between the chassis side connector terminal
No.B69–5 (+) and No.B69–1 (-)? — Go to Step 5 Go to Step 4
— Varify repair —
5
terminal No.B69–1 and No.I32–4? — Go to Step 7 Go to Step 6
6 Repair an open circuit between terminal No.B69–1 and
No.I32–4.
No.I32–3.
9 Replace the mode actuator.
Chart B: Mode Actuator Control Failure

1 Turn on the ignition switch (the engine is run).
Dose the mode actuator fully stroke when the defrost
mode and the vent mode are selected? — Go to Step 3 Go to Step 2
2 Repair or replace the mode door or the link unit.
No.I33–11.
No.I33–10.
7 Is there continuity between harness side connector
No.I33–8.
9 Is sum of the voltage between the following harness
side connector terminal approximately 5V? Voltage
between No.I33–8 and No.I33–10 plus voltage
between No.I33–8 and No.I33–11 5V Go to Step 11 Go to Step 10
10 Replace the actuator.
11 Dose the mode actuator work normally through manual
operation? — Go to Step 13 Go to Step 12
12 Replace the sensor.
Inspection of the Fan Motor System
D08RY00144

The fan dose not rotate at all — Refer to Chart A
The fan dose not rotate in the — Refer to Chart B
MAX–HI mode
The fan dose not rotate in any mode — Refer to Chart C
other than MAX–HI
The fan dose not stop — Refer to Chart D
Chart A: Fan Does Not Rotate At All

1
Replace the
Are the fuse No.C–19 and No.C–20 normal? — Go to Step 2 fuse
2 Are the relay No.B–36 and No.I–51 normal? Replace the
3 Turn on the ignition switch (the engine is run).
connector terminal No.B5–1 and ground? — Go to Step 5 Go to Step 4
No.C–19 fuse.
terminal No.B5–2 and ground (No.B–2)? — Go to Step 7 Go to Step 6
ground.
Is the action complete? — — —
connector terminal No.B5–2 and No.B5–1? — Go to Step 8 Go to Step 9
8 Replace the blower motor.
9 Refer to chart B and C.
Chart B: Fan Does Not Rotate in MAX HI Mode

1 Is the MAX-HI relay (I–51) normal? Replace the
2. Set the fan switch to the MAX-HI.
No.I51–2.
terminal No.I51–4 and ground (No.B–2)? — Go to Step 6 Go to Step 5
ground (No.B–2).
connector terminal No.I51–1 and ground? — Go to Step 8 Go to Step 7
No.C–20 fuse.
No.I32–12.
Chart C: Fan Does Not Rotate In Any Mode Other Than MAX HI
1 Is the power transistor performance normal? (Refer to Replace the
the later section on “individual inspection”) power
— Go to Step 2 transistor
terminal No.B5–2 and No.I50–1, No.B5–2 and
No.I33–17? — Go to Step 4 Go to Step 3
3 Repair an open circuit between terminal.
No.B5–2 and I50–1
No.B5–2 and I33–17
— Go to Step 2 —
terminal No.I50–3 and ground (No.B–2)? — Go to Step 6 Go to Step 5
ground.
No.I33–19.
Chart D: Fan Does Not Stop

1 1. Disconnect the max high relay, the power transistor
connector I–50 and the auto A/C control unit
connector I–33.
2. Turn on the ignition switch.
Does the blower motor stop? — Go to Step 3 Go to Step 2
2 Repair a short circuit between connector No.B5–2 and
No.I51–2, No.B5–2 and No.I50–1, or No.B5–2 and
I33–17.
3 Is the max high relay normal? (Refer to the later Replace the
section on “individual inspection”.) — Go to Step 4 relay
4 Reinstall the max high relay.
Does the blower motor start operating? — Go to Step 6 Go to Step 5
5 Repair a short circuit between connector No.I51–3 and
No.I32–12.
6 Is the power transistor normal? (Refer to the later Replace the
section on “individual inspection”.) power
— Go to Step 7 transistor
7 Reinstall the power transistor. Replace the
auto A/C
Does the blower motor start operating?
— control unit —
Inspection of the Magnetic Clutch System

6VE1 Engine
D08RY00143

Magnetic clutch does not work — Refer to Chart A
Chart A: Magnetic Clutch Does Not work

1 Is the fuse No.C–20 normal? Replace the
2 Is the relay No.X–7 (compressor relay) No.X–5 (A/C Replace the
thermo relay) and No.B–36 (heater relay) normal? — Go to Step 3 fuse
3 Is the thermo unit normal? Replace the
— Go to Step 4 thermo unit
4 Is the pressure switch normal? Replace the
pressure
— Go to Step 5 switch
5 1. Turn the ignition switch on. (the engine is run.)
2. Push the air conditioner switch on.
connector terminal No.E3–1 and the ground? — Go to Step 6 Go to Step 7
6 Repair or replace the magnetic clutch.
terminal No.X7–4 and No.E3–1? — Go to Step 9 Go to Step 8
8 Repair an open circuit between terminal No.X7–4 and
No.E3–1.
connector terminal No.X7–2 and ground, No.X7–1 and
ground? — Go to Step 11 Go to Step 10
fuse No.C–20, No.X7–1 and fuse No.C–20.
No.X7–3.
connector terminal No.C25–1 and ground? — Go to Step 15 Go to Step 14
14 Repair an open circuit between terminal No.C25–1 and
fuse No.C–20.
connector terminal No.X5–3 and ground, No.X5–2 and
No.C25–2, No.X5–2 and fuse No.C–20.
Chart A: Magnetic Clutch Does Not work (Cont’d)

I32–14.
terminal No.I33–4 and ground? — Go to Step 21 Go to Step 20
No.E19–1.
21 Dose the thermo relay “ON” when connecting ground to
the harness connector terminal No.H16–6? — Go to Step 23 Go to Step 22
22 Failure on the auto air conditioner control unit.
CAUTION: There are conditions which air

conditioner system dose not operate except trouble
as follows.
1. The throttle is griater than 90%.
2. The ignition voltage is below 10.5 volts.
3. The engine speed greater than 4500 RPM for 5
seconds or 5400 RPM.
4. The engine coolant temperature (ECT) is greater
than 257°F.
5. The intake air temperature (IAT) is less than 41°F.
6. The power steering pressure switch signals a
high pressure condition.
Individual Inspection Sun Sensor

In Car Sensor 1. Disconnect the sun sensor connector (I–35).
2. Measure the current value on the sun sensor when
1. Disconnect the in car sensor connector (I–34). placed it approximately 15 cm away from 60W
2. Measure resistance between the in car sensor side incandescent lamp.
terminal No.I34–3 and No.I34–4.
D06RY00001
Ambient Sensor
1. Disconnect the connector (C–86) on the ambient
sensor.
2. Measure resistance between the ambient sensor side
terminals.
865RY00011
C01RY00006
Power Transistor In Car Sensor
1. Remove the power transistor connector (I–50) from 1. Turn on the ignition switch (the engine is started).
the evaporator assembly. Start the air conditioner in “Full Auto”.
2. Check the conduction between the power transistor 2. Make sure that the in car sensor suctions cigarette
side terminals. smokes and such.
In Car Sensor
1. Dismount the in car sensor from the automatic
heater/air conditioner control unit. Connect (+) end
and (–) end of the battery to the aspirator motor side
terminals No.I34–1 and No.I34–2, respectively, then
check if the motor runs normally.
C01RY00002
MAX HI Relay
1. Remove the MAX – HI relay connector (I–51) from the
blower assembly.
2. Check the conduction between the MAX – HI relay
side terminals.
C01RY00005
C01RY00003
Heater (B–36), Thermostat (X–5), And
Compressor (X–7) Relay
1. Disconnect relays and check for continuity and
resistance between relay terminals.
D For handling of these relays, refer to Heater Relay
in this section.
901RY00041
Triple Pressure Switch (V6, A/T)

1. Disconnect the connector and check for continuity
between pressure switch side connector terminals (1)
and (2).
2. Reconnect the connector to activate the A/C switch,
and check to see if there is continuity between the
chassis side connector terminal (3) and (4) and the
fan operates.
875RX009
On-Vehicle Service
Power Transistor Automatic Heater/Air Conditioner
Control Unit
874RY00010
Legend 865RY00012
(1) Evaporator Assembly Legend

(2) Power Transistor (1) Connector
(3) Power Transistor Connector (2) Set Screw
(4) Instrument Panel Passenger Lower Cover (3) Instrument Panel Cluster
(5) Glove Box (4) Automatic Heater/Air Conditioner Control Unit
(6) Front Console
(7) Lower Cluster
(8) Passenger Knee Bolster Reinforcement Removal
Removal 2. Remove instrument panel cluster.
D Refer to Instrument Panel Assembly in Body
1. Remove front console. Stractur section.
2. Remove lower cluster. 3. Disconnnect the automatic heater/air conditioner
3. Remove glove box. control unit connector.
4. Remove instrument panel passenger lower cover. 4. Remove automatic heater/air conditioner control unit.
5. Remove passenger knee bolster reinforcement.
6. Disconnect the power transistor connector. Installation
7. Remove power transistor. To install, follow the removal step in the reverse order.
Installation
To install, follow the removal step in the reverse order.
In Car Sensor Ambient Sensor
865RY00020 875RY00001
Legend Legend
(1) In Car Sensor (1) Ambient Sensor
(2) Automatic Heater/Air Conditioner Control Unit (2) Sensor Connector
(3) Radiator Grille
Removal
Removal
2. Remove the automatic heater/air conditioner control 1. Disconnect the battery ground cable.
unit. 2. Remove radiator grille.
D Refer to the automatic heater/air conditioner control D Refer to Radiator Grille in Body Structure section.
unit section. 3. Disconnect the ambient sensor connector.
3. Remove in car sensor. 4. Remove the ambient sensor.
Installation Installation
To install, follow the removal step in the reverse order. To install, follow the removal step in the reverse order.
Sun Sensor Electronic Thermostat
826RY00012
Legend
(1) Sun Sensor
Removal
2. Remove the sun sensor.
3. Disconnect the sun sensor connector.
874RX022
Installation Legend
(1) Duct Sensor
(2) Evaporator Core
(4) Thermostat Assembly
Removal
D Refer to evaporator assembly section.
3. Remove electronic thermostat.
Installation
Mode Actuator Mix Actuator
860RY00008 860RY00009
Legend Legend
(1) A/T Control Unit (1) Instrument Panel Assembly
(2) Actuator Rod (2) Actuator Rod
(3) Mode Actuator (3) Mix Actuator
(4) Instrument Panel Center Bracket
Removal
Removal
2. Remove the PCM. 1. Disconnect the battery ground cable.
D The connector shall remain connected. 2. Remove the instrument panel assembly.
3. Remove the actuator rod. D Refer to the Instrument Panel Assembly in Body
4. Remove the mode actuator. and Accessories section.
3. Remove the instrument panel center bracket.
4. Remove the actuator rod.
Installation
5. Remove the mix actuator.
To install, follow the remove step in the reverse order.
Installation
Intake Actuator
873RY00004
Legend
(2) Intake Actuator
(3) Intake Actuator Connector
Removal
3. Remove the evaporator assembly.
D Refer to Evaporator Assembly section.
4. Disconnect the intake actuator connector.
5. Remove the intake actuator.
Installation
POWER ASSISTED SYSTEM 2A–1
TROOPER
STEERING
POWER ASSISTED SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 2A–2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–38
General Description . . . . . . . . . . . . . . . . . . . . . 2A–2 Relay Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–39
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–5 Relay Lever and Associated Parts . . . . . . . 2A–39
Power Steering System Test . . . . . . . . . . . . . . 2A–11 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–39
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–40
Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–12 Steering Linkage and Associated Parts . . . . 2A–41
Bleeding The Power Steering System . . . . . . 2A–12 Main Data and Specifications . . . . . . . . . . . 2A–41
Bleeding Procedure . . . . . . . . . . . . . . . . . . . . . 2A–12 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–42
Flushing The Power Steering System . . . . . . 2A–12
Supplemental Restraint System Steering
Steering Wheel Free Play Adjustment . . . . . . 2A–13 Wheel & Column . . . . . . . . . . . . . . . . . . . . . . . 2A–43
Front End Alignment Inspection and Service Precaution . . . . . . . . . . . . . . . . . . . . 2A–43
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–13
SRS Connectors . . . . . . . . . . . . . . . . . . . . . . 2A–43
Main Data and Specifications . . . . . . . . . . . . . 2A–18
Inflator Module . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–45
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–19
Inflator Module and Associated Parts . . . . . 2A–45
Power Steering Gear . . . . . . . . . . . . . . . . . . . . 2A–20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–45
Power Steering Gear and Associated
Inspection and Repair . . . . . . . . . . . . . . . . . . 2A–46
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–46
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–20
Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . 2A–47
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–21
Steering Wheel and Associated Parts . . . . 2A–47
Steering Gear Disassembled View . . . . . . . 2A–22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–47
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–49
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–25 Combination Switch . . . . . . . . . . . . . . . . . . . . . 2A–50
Main Data and Specifications . . . . . . . . . . . 2A–27 Combination Switch and Associated Parts 2A–50
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–50
Power Steering Pump . . . . . . . . . . . . . . . . . . . . 2A–28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–52
Power Steering Pump and Associated
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–28 Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–54
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–28 Lock Cylinder and Associated Parts . . . . . . 2A–54
Power Steering Pump Disassembled View 2A–30 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–56
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–30 System Inspection . . . . . . . . . . . . . . . . . . . . . 2A–57
Inspection and Repair . . . . . . . . . . . . . . . . . . 2A–31 Steering Column . . . . . . . . . . . . . . . . . . . . . . . . 2A–58
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–32 Steering Column and Associated Parts . . . 2A–58
Main Data and Specifications . . . . . . . . . . . 2A–33 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–58
Center Track Rod Assembly . . . . . . . . . . . . . . 2A–34 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–60
Center Track Rod Assembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–62
Associated Parts . . . . . . . . . . . . . . . . . . . . . . 2A–34 System Inspection . . . . . . . . . . . . . . . . . . . . . 2A–63
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–35 Supplemental Restraint System Steering
Inspection and Repair . . . . . . . . . . . . . . . . . . 2A–35 Wheel & Column and Associated Parts . . . . 2A–64
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–35 Main Data and Specifications . . . . . . . . . . . 2A–64
Outer Track Rod Assembly . . . . . . . . . . . . . . . 2A–36 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–65
Outer Track Rod Assembly and
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–37
2A–2 POWER ASSISTED SYSTEM

systems.
General Description
The hydraulic power steering system consists of a pump,
an oil reservoir, a steering gear, a pressure hose and a
return hose.
Power Steering Gear
A03RS001
The power steering gear has a recirculating ball system The control valve in the steering gear directs the power
which acts as a rolling thread between the worm shaft and steering fluid to either side of the rack piston.
the rack piston. When the worm shaft is turned right, the The rack piston converts the hydraulic pressure into a
rack piston moves up in gear. mechanical force. If the steering system becomes
Turning the worm shaft left moves the rack piston down in damaged and loses hydraulic pressure, the vehicle can
gear. The rack piston teeth mesh with the sector gear, be controlled manually.
which is part of the sector shaft.
Turning the worm shaft turns the sector shaft, which turns
the wheels through the steering linkage.
Hydraulic Pump
442RV006
The hydraulic pump is a vane-type design. There are two Pressure Switch
openings at the rear of the pump housing. The larger When hydraulic pressure reaches 3650 ± 350 kPa (530 ±
opening contains the cam ring, pressure plate, thrust 50 psi), the pressure switch of the power steering pump
plate, rotor and vane assembly, and end plate. The closes causing the Powertrain Control Module (PCM) to
smaller opening contains the pressure line union, flow actuate the idle air control valve, which increases the
control valve and spring. engine rpm to prevent the overload-induced engine
speed slow down. The switch opens when hydraulic
pressure drops to 3150 ± 350 kPa (460 ± 50 psi).
Steering Linkage
433RS007
Legend (4) Relay Lever

(1) Center Track Rod Assembly (5) Rod End,Outer
(2) Outer Track Rod Assembly (6) Track Rod
(3) Pitman Arm (7) Rod End,Inner
The steering linkage consists of a pitman arm, relay lever,

center track rod, and two adjustable outer track rods.
When the steering wheel is turned, the gear rotates the
pitman arm which forces the center track rod to one side.
The outer track rods, connected to the center track rod by
ball studs, transfers the steering force to the wheels. The
outer track rods are adjustable and are used for toe-in
adjustments. The center track rod is supported by the
pitman arm and relay lever. The relay lever pivots on a
support attached to the frame.
The overall condition of the steering linkage affects
steering performance. If parts are bent, damaged, worn
or poorly lubricated, improper and possibly dangerous
steering action will result.
Whenever any steering linkage components are repaired
or replaced, check the steering geometry and front end
alignment. Refer to Front End Alignment Inspection and
Adjustment in this section.
Steering Column 3. With the column mounted lock, the ignition and
steering operation can be locked to prevent theft of
WARNING: TO AVOID DEPLOYMENT WHEN the vehicle.
TROUBLE-SHOOTING THE SRS SYSTEM, DO NOT The column can be disassembled and reassembled.
USE ELECTRICAL TEST EQUIPMENT, SUCH AS However, to ensure the energy absorbing action, use only
BATTERY-POWERED OR A/C-POWERED the specified screws, bolts and nuts as designated, and
VOLT-METER, OHMMETER, ETC., OR ANY TYPE OF tighten them to the specified torque.
ELECTRICAL EQUIPMENT OTHER THAN
Handle the column with care when it is removed from the
SPECIFIED IN THIS MANUAL. DO NOT USE A
vehicle. A sharp blow on the end of steering shaft or shift
NON-POWERED PROBE-TYPE TESTER.
lever, or dropping the assembly could shear or loosen the
INSTRUCTION IN THIS MANUAL MUST BE FOL- fasteners that maintain column rigidity.
LOWED CAREFULLY, OTHERWISE PERSONAL IN-
JURY MAY RESULT.
Diagnosis
When servicing a vehicle equipped with Supplemental Since the problems in steering, suspension, wheels and
Restraint System, pay close attention to all WARNINGS tires involve several systems, they must all be considered
and CAUTIONS. when diagnosing a complaint. To identify the symptom,
For detailed explanation about SRS, refer to Restraints always road test the vehicle first. Proceed with the follow-
section. ing preliminary inspections and correct any defects which
are found.
The steering column has three important features in
addition to the steering function: 1. Inspect tires for proper pressure and uneven wear.
1. The column is energy absorbing, designed to 2. Raise vehicle on a hoist, then inspect front and rear
compress in a front-end collision to minimize the suspension and steering linkage for loose or
possibility of injury to the driver of the vehicle. damaged parts.
2. The ignition switch and lock are mounted 3. Spin the front wheels. Inspect for out-of-round tires,
conveniently on the column. out-of-balance tires, loose and/or rough wheel
bearings.
General Diagnosis
Vehicle Pulls Mismatched or uneven tires. Replace tire.
Tires not adequately inflated. Adjust tire pressure.
Broken or sagging springs. Replace spring.
Radial tire lateral force. Replace tire.
Improper wheel alignment. Adjust wheel alignment.
Brake dragging in one wheel. Repair brake.
Loose, bent or broken front or rear Tighten or replace the appropriate
suspension parts. suspension part(s).
Faulty shock absorbers. Replace shock absorber.
Abnormal or Excessive Tire Wear Sagging or broken spring. Replace spring.
Tire out of balance. Balance or replace tire.
Improper wheel alignment. Check front end alignment.
Faulty shock absorber. Replace shock absorber.
Hard driving. Replace tire.
Overloaded vehicle. Replace tire and reduce load.
Tires not rotated periodically. Replace or rotate tire.
Worn or loose road wheel bearings. Replace wheel bearing.
Wobbly wheel or tires. Replace wheel or tire.
Tires not adequately inflated. Adjust the pressure.
Wheel Hop Blister or bump on tire. Replace tire.
Improper shock absorber operation. Replace shock absorber.

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

Abnormal Noise Worn, sticky or loose upper or lower Replace.
ball joint, steering linkage ball joints
or drive axle joints.
Faulty shock absorbers. Replace.
Worn upper or lower control arm Replace.
bushing.
Loose stabilizer bar. Retighten bolts or replace bushings.
Loose wheel nuts. Tighten nuts. Check for elongated
wheel nut holes.
Replace wheel if required.
Loose suspension bolts or nuts. Retighten suspension bolts or nuts.
Broken or otherwise damaged wheel Replace wheel bearing.
bearings.
Broken suspension springs. Replace spring.
Loose steering gear. Retighten mounting bolt.
Faulty steering gear. Check and adjust steering gear.
Wandering or Poor Steering Stability Mismatched or unevenly worn tires. Replace tire or inflate tires to proper
pressure.
Loose steering linkage ball joints. Replace ball joints.
Loose stabilizer bar. Tighten or replace stabilizer bar or
bushings.
Broken or sagging springs. Replace spring (pairs).
Steering gear misadjustment. Check or adjust steering gear.
Erratic Steering When Braking Worn wheel bearings. Replace wheel bearings.
Leaking caliper. Repair or replace caliper.
Warped discs. Replace brake disc.
Badly worn brake pads. Replace brake pads.
Tires are inflated unequally. Inflate tires to proper pressure.
Power Steering System
There is some noise in all power steering systems. One tween this noise and steering performance. Do not re-
of the most common is a hissing sound when the steering place the valve unless the “hissing” noise is extremely ob-
wheel is fully turned and the car is not moving. This noise jectionable. A replacement valve will also have a slight
will be most evident when the steering wheel is operated noise, and is not always a cure for the condition.
while the brakes are applied. There is no relationship be-
Rattle or Chucking Noise Pressure hose touching other parts Adjust hose position. Do not bend
of vehicle. tubing by hand.
Tie rod ends loose. Tighten or replace tie rod end.
Loose steering gear mounting. Tighten steering gear mounting.
Steering gear misadjustment. Check and adjust steering gear
preload.
Poor Return of Steering Wheel to Improper front wheel alignment. Adjust front wheel alignment.
Center
Wheel bearing worn. Replace front wheel bearing.
Tie rod end binding. Replace tie rod end.
Ball joint binding. Replace ball joint.
Tight or frozen steering shaft Replace steering assembly.
bearing.
Steering gear misadjustment. Adjust the steering gear.
Sticky or plugged steering gear Repair or replace steering gear
valve. valve.
Entry of air in the power steering Bleed the system.
system.
Momentary Increase In Effort When High internal leakage. Repair steering gear.
Turning Wheel Fast To Right or Left
Power steering fluid level low. Replenish fluid.
Steering Wheel Surges or Jerks Insufficient pump pressure. Repair pump assembly.
When Turning Especially During
Sticky steering gear valve. Repair or replace steering gear.
Parking
Excessive Wheel Kick Back or Loose Air in system. Bleed hydraulic system.
Steering
Tie rod end loose. Tighten tie rod end.
Wheel bearing worn. Replace wheel bearing.
Hard Steering or Lack of Power Sticky steering gear valve. Repair or replace steering gear
Assist valve.
Insufficient pump pressure. Repair pump assembly.
Excessive internal pump leakage. Repair pump assembly.
Excessive internal steering gear Repair steering gear.
leakage.
Unstable Engine Idling or Stalling Pressure switch of the power Repair or replace.
When Turning steering pump or its harness is faulty.
Power Steering Pump

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

Will Not Unlock Damaged lock cylinder. Replace lock cylinder.
Damaged park lock cable. Replace park lock cable.
Will Not Lock Lock spring broken or worn. Replace lock cylinder.
Damaged lock cylinder. Replace lock cylinder.
Ignition switch stuck. Repair or replace ignition switch.
Park lock cable damaged. Replace park lock cable.
Key Cannot be Removed in Ignition switch is not set correctly. Correct ignition switch.
“OFF LOCK”
“OFF-LOCK”
Faulty shift lock mechanism. Repair or replace the shift lock
mechanism.
Column
Noise in Column Universal joint loose. Tighten joint.
Shaft lock snap ring not seated. Place snap ring in proper position.
Turn Signal Switch
This diagnosis covers mechanical problems only. Refer
to Turn Signal Switch in Electrical section for electrical
diagnosis.
Turn Signal Will Not Stay In Turn Foreign material or loose parts Repair or replace signal switch.
Position preventing movement of yoke.
Broken or missing detent or Replace signal switch.
canceling spring.
Turn Signal Will Not Cancel Loose switch mounting screws. Tighten mounting screws.
Switch or anchor bosses broken. Replace turn signal switch.
Broken, missing or out of position Replace turn signal switch.
detent, return or canceling spring.
Worn canceling cam. Replace turn signal switch.
Turn Signal Difficult To Operate Turn signal switch arm loose. Tighten arm screw.
Broken or distorted yoke. Replace turn signal switch.
Loose or misplaced springs. Replace turn signal switch.
Foreign parts and/or material. Repair turn signal switch.
Loose turn signal switch mounting Tighten mounting screws.
screws.
Turn Signal Will Not Indicate Lane Broken lane change pressure pad or Replace turn signal switch.
Change spring hanger.
Broken, missing or misplaced lane Replace turn signal switch.
change spring.
Base of wire damaged. Replace turn signal switch.
Hazard Switch Cannot Be Turned Off Foreign material between hazard Repair or replace hazard switch.
switch to turn signal switch body.
No Turn Signal Lights Electrical failure in chassis harness. Refer to Electrical section.
Inoperative turn signal flasher unit. Replace flasher unit.
Loose chassis harness connector. Repair loose connector.
Front or Rear Turn Signal Lights Not Burned-out or damaged turn signal Replace bulb.
Flashing bulb.
High resistance connection to Repair bulb socket.
ground at bulb socket.
Power Steering System Test

Test Procedure
F02RX001
Legend (3) To Power Steering Gear

(1) Bolt (M16 × 1.5) (4) To Power Steering Pump
(2) Hose (Vehicle Side)
Test of fluid pressure in the power steering system is 4. Bleed the system. Refer to Bleeding the Power
performed to determine whether or not the oil pump and Steering System in this section.
power steering unit are functioning normally. 5. Start the engine and check the pump fluid level. Add
The power steering system test is the method used to power steering fluid if required. When the engine is at
identify and isolate hydraulic circuit difficulties. Prior to normal operating temperature, increase engine
performing this test, the following inspections and speed to 1500 rpm.
corrections, if necessary, must be made.
CAUTION: Do not leave shutoff valve fully closed
D Inspect pump reservoir for proper fluid level. for more than 5 seconds, as the pump could become
D Inspect pump belt for proper tension. damaged internally.
D Inspect pump driver pulley condition. 6. Fully close the shutoff valve. Record the highest
1. Place a container under the pump to catch the fluid pressures.
when disconnecting or connecting the hoses. D If the pressure recorded is within 9300–9800 kPa
2. With the engine NOT running,disconnect the (1350–1420 psi), the pump is functioning within its
pressure hose at the power steering pump and install specifications.
power steering tester J-29877-A. The gauge must be D If the pressure recorded is higher than 9800 kPa
between the shutoff valve and pump. Open the (1420 psi), the valve in the pump is defective.
shutoff valve.
D If the pressure recorded is lower than 9300 kPa
3. Check the fluid level. Fill the reservoir with power (1350 psi), the valve or the rotating group in the
steering fluid, to the “Full” mark. Start the engine, pump is defective.
then turn the steering wheel and momentarily hold it
against a stop (right or left). Turn the engine off and
check the connections at tester for leakage.
7. If the pump pressures are within specifications, leave Bleeding The Power Steering System
the valve open and turn (or have someone else turn)
the steering wheel fully in both directions. Record the When a power steering pump or gear has been installed,
highest pressures and compare with the maximum or an oil line has been disconnected, the air that has
pump pressure recorded in step 6. If this pressure entered the system must be bled out before the vehicle is
cannot be built in either side of the power steering operated. If air is allowed to remain in the power steering
gear, the power steering gear is leaking internally and fluid system, noisy and unsatisfactory operation of the
must be disassembled and repaired. system may result.
8. Shut the engine off, remove the testing gauge.
9. Reconnect the pressure hose, check the fluid level Bleeding Procedure
and make the needed repairs. When bleeding the system, and any time fluid is added to
10. If the problem still exists, the steering and front the power steering system, be sure to use only power
suspension must be thoroughly examined. steering fluid as specified in General Information.
1. Fill the pump fluid reservoir to the proper level and let
the fluid settle for at least two minutes.
Maintenance 2. Start the engine and let it run for a few seconds. Do
The hydraulic system should be kept clean and fluid level not turn the steering wheel. Then turn the engine off.
in the reservoir should be checked at regular intervals and
3. Add fluid if necessary.
fluid added when required. Refer to Recommended
Fluids and Lubricants in General Information section for 4. Repeat the above procedure until the fluid level
the type of fluid to be used and the intervals for filling. remains constant after running the engine.
If the system contains some dirt, flush it as described in 5. Raise and support the front end of the vehicle so that
this section. If it is exceptionally dirty, both the pump and the wheels are off the ground.
the gear must be completely disassembled before further 6. Start the engine. Slowly turn the steering wheel right
usage. and left, lightly contacting the wheel stops.
All tubes, hoses, and fittings should be inspected for
7. Add power steering fluid if necessary.
leakage at regular intervals. Fittings must be tight. Make
sure the clips, clamps and supporting tubes and hoses 8. Lower the vehicle, set the steering wheel at the
are in place and properly secured. straight forward position after turning it to its full steer
Power steering hoses and lines must not be twisted, positions 2 or 3 times, and stop the engine.
kinked or tightly bent. Air in the system will cause spongy 9. Check the fluid level and refill as required.
action and noisy operation. When a hose is disconnected 10. If the fluid is extremely foamy, allow the vehicle to set
or when fluid is lost, for any reason, the system must be a few minutes, then repeat the above procedure.
bled after refilling. Refer to Bleeding the Power Steering
System in this section.
D Inspect belt for tightness. Flushing The Power Steering System
D Inspect pulley for looseness or damage. The pulley 1. Raise and support the front end of the vehicle off the
should not wobble with the engine running. ground until the wheels are free to turn.
D Inspect hoses so they are not touching any other 2. Remove the fluid return line at the pump inlet
parts of the vehicle. connector and plug the connector port on the pump.
D Inspect fluid level and fill to the proper level. Position the line toward a large container to catch the
draining fluid.
Fluid Level 3. While running the engine at idle, fill the reservoir with
new power steering fluid. Turn the steering wheel in
1. Run the engine until the power steering fluid reaches both directions. Do not contact or hold the steering
normal operating temperature, about 55°C (130°F), wheel to the wheel stops. This will cause the pump to
then shut the engine off. go to pressure relief mode, which may cause a
2. Check the level of fluid in the reservoir. sudden fluid overflow at the reservoir.
3. If the fluid level is low, add power steering fluid as
specified in General Information to the proper level
and install the receiver cap.
4. When checking the fluid level after the steering
system has been serviced, air must be bled from the
system. Refer to Bleeding the Power Steering
4. Install all the lines and hoses. Fill the system with new Adjustment
power steering fluid and bleed the system as
described in Bleeding The Power Steering System.
Operate the engine for about 15 minutes.
Remove the pump return line at the pump inlet and
plug the connection on the pump. While refilling the
reservoir, check the draining fluid for contamination.
If foreign material is still evident, replace all lines,
disassemble and clean or replace the power steering
system components. Do not re-use any drained
power steering fluid.
Steering Wheel Free Play Adjustment

Inspection
431RS001
1. Align the front wheels properly in the straight ahead

position.
2. Loosen the lock nut on the adjusting screw of the
steering gear.
3. Turn the adjust screw clockwise to decrease free play
or counter-clockwise to increase.
4. After check of specified free play, tighten the lock nut
to specified torque.
Torque: 41 N·m (30 lb ft)
Front End Alignment Inspection and

430RS015 Adjustment
1. With the tires in the straight-ahead position, check the
amount of steering wheel play by turning the wheel in
General Description
both directions until the tires begin to move. “Front End Alignment” refers to the angular relationship
between the front wheels, the front suspension attaching
NOTE: The wheel free play should be checked with the parts and the ground.
engine running. Proper front end alignment must be maintained in order to
Free play: 0 – 30 mm (0 – 1.18 in) insure efficient steering, good directional stability and to
2. Also check the steering wheel for play and looseness prevent abnormal tire wear.
in the mount by moving it back and forth and The most important factors of front end alignment are
sideways. When test driving, check for hard steering, wheel toe-in, wheel camber and axle caster.
steering shimmy and tendency to pull to one side.
Camber: Caster(1) is the vertical tilting of the wheel axis either
This illustration is viewed from the front of the vehicle. forward or backward (when viewed from the side of the
vehicle). A backward tilt is positive(+) and a forward tilt is
negative (–). On the short and long arm type suspension
you cannot see a caster angle without a special
instrument, but if you look straight down from the top of
the upper control arm to the ground, the ball joints do not
line up (fore and aft) when a caster angle other than 0
degree is present. With a positive angle, the lower ball
joint would be slightly ahead (toward the front of the
vehicle) of the upper ball joint center line.
Toe-in:
This illustration is viewed from the top of the vehicle.
480RS004
Camber is the vertical tilting inward or outward of the front

wheels. When the wheels tilt outward at the top, the
camber is positive (+). When the wheels tilt inward at the
top, the camber is negative (–). The amount of tilt
measured in degrees from the vertical is called the
camber angle (1). If camber is extreme or unequal
between the wheels, improper steering and excessive tire
wear will result. Negative camber causes wear on the
inside of the tire, while positive camber causes wear to the
outside.
Caster: 480RS003
This illustration is viewed from the side of the vehicle. Toe-in is the measured amount the front wheels are
turned in. The actual amount of toe-in is normally a
fraction of a degree. Toe-in is measured from the center
of the tire treads or from the inside of the tires. The
purpose of toe-in is to insure parallel rolling of the front
wheels and to offset any small deflections of the wheel
support system which occurs when the vehicle is rolling
forward. Incorrect toe-in results in excessive toe-in and
unstable steering. Toe-in is the last alignment to be set in
the front end alignment procedure.
Inspection
Before making any adjustments affecting caster, camber
or toe-in, the following front end inspection should be
made.
1. Inspect the tires for proper inflation pressure. Refer to
Main Data and Specifications in Wheel and Tire
System section.
2. Make sure that the vehicle is unladen condition (With
no passenger or loading).
480RS005
3. Make sure that the spare tire is installed at the normal
position.
4. Inspect the front wheel bearings for proper
adjustment. Refer to Front Hub and Disc Overhaul in
Suspension section.
5. Inspect the ball joints, tie rod ends and relay rods. If
excessive looseness is noted, correct before
adjusting. Refer to Steering Linkage in this section.
6. Inspect the wheels and tires for run-out. Refer to 1. Check and adjust the tire inflation pressures.
Wheel Replacement in Wheel and Tire System 2. Park the vehicle on a level ground and move the front
section. of the vehicle up and down several times to settle the
7. Inspect the trim height. If not within specifications, suspension.
the correction must be made before adjusting caster. 3. Make necessary adjustment with the adjusting bolt on
8. Inspect the steering gear for looseness at the frame. the height control arms.
9. Inspect the shock absorbers for leaks or any Trim height: 129 mm (5.08 in)
noticeable noise. Refer to Shock Absorber
Replacement in Suspension section. Caster Adjustment
10. Inspect the control arms or stabilizer bar attachment The caster angle can be adjusted by means of the caster
for looseness. Refer to Suspension section . shims(1) installed between the chassis frame(2) and
11. Inspect the front end alignment using alignment fulcrum pins.
equipment. Follow the manufacturer’s instructions.
Caster angle: 2°10’ ± 45’
12. Park the vehicle must be on a level surface.
CAUTION: Left and right side must be equal within
Trim Height Adjustment 30’.
Adjust the trim height(1) by means of the adjusting bolt on
the height control arms.
CAUTION: When adjusting front end alignment, be
sure to begin with trim height first, as it may change
other adjusted alignments.
450RS001
450RS003
450RS002
NOTE: Difference of the caster shim front/rear thickness

should be 3.6 mm (0.142 in) or less. Overall thickness of
caster shim and camber shim should be 10.8 mm
(0.425 in) or less.
410RS001
Tighten the fulcrum pin bolt to the specified torque.
Camber Adjustment
The camber angle can be adjusted by means of the
camber shims(2) installed in position between the chassis
frame(1) and fulcrum pins
Camber angle: 0° ± 30’
King pin inclination: 12°30’ ± 30’
CAUTION: Left and right side must be equal within
30’.
450RS005
NOTE: Overall thickness of caster shim and camber

shim should be 10.8 mm (0.425 in) or less.
450RS004
Position of shims
Camber angle Caster angle
Front side Rear side
When added When removed Decreases Decreases
When removed When added Increases Increases
Caster shim
— When removed Unchanged Decreases
— When added Unchanged Increases
When added Decreases Unchanged
Camber shim
When removed Increases Unchanged
Toe-in Adjustment 3. Adjust the inside wheel angle of each side with the
stop bolts.
1. To adjust the toe-in angle, loosen the lock nuts(2) on
the outer track rods(1) and turn the outer track rods. NOTE: The maximum protruding length(1) of stop bolt(3)
Turn both rods the same amount, to keep the steering from the lock nut(2) should be 10 mm or less
wheel centered .
Toe-in: 0 ± 2 mm (0 ± 0.08 in)
433RS003
4. Similarly adjust the inside wheel angle of the other

side with stop bolt.
433RS001
2. Tighten the lock nut to the specified torque. Inside wheel: 34° (+0° to –2°)
Torque: 118 N·m (87 lb ft) Outside wheel: 32°
NOTE: Maximum steering angles should be set after
Maximum Steering Angle Adjustment adjusting front wheel alignment.
The maximum steering angle of the front wheels can be
5. If the stop between the lower link end and the knuckle
adjusted with the stop bolts under the frame side
comes ahead of the stop bolt, adjust the stop bolt so
members. that inner stop bolt touches the drop arm (relay lever).
433RS002
433RS004
1. Position each front wheel on the turning radius gauge 6. Tighten the lock nut to the specified torque.
in a straight-ahead position.
2. Set the parking brake firmly.
Main Data and Specifications

General Specification
Caster 2°10’ ± 45’
Camber 0° ± 30’
King pin inclination 12°30’ ± 30’
Toe-in 0 ± 2 mm (0 ± 0.08 in)
Max. steering angle inside 34° (+0° to –2°)
outside 32°
Torque Specification
E03RS001
Special Tools
TOOL NO.
ILLUSTRATION
TOOL NAME
J–29877–A
Tester:
Power steering
J–39213
Adapter:
Power steering tester
J–29107
Remover:
Pitman arm
J–26508
Installer:
Extension housing oil
seal
Power Steering Gear

Power Steering Gear and Associated Parts
431RS002
Legend (4) Nut

(1) Pipe (5) Gear Box Mounting Bolt and Nut
(2) Universal Joint Bolt (6) Gear Box
(3) Pitman Arm
Removal
1. Remove the stone guard.
2. Remove the lower fan shroud. Refer to Radiator in
Engine section.
3. Disconnect stabilizer bar at the stabilizer links.
Loosen stabilizer bracket fixing nuts.
4. Remove pipe.
5. Remove nut.
6. Use Pitman arm remover J–29107 to remove pitman
arm.
433RS005
7. Make a setting mark(1) across the coupling flange
and worm shaft to ensure reassembly of the parts in
the original position, then remove universal joint bolt.
431RW004
2. Tighten gear box mounting bolt and nut to specified

torque.
431RW004 Torque: 44 N·m (33 lb ft)
8. Push the stabilizer bar aside and remove the gear box 3. Tighten gear universal joint bolt to specified torque.
mounting bolts and nuts.
4. Align the notched tooth and install pitman arm.
431RS004
9. Remove gear box.

433RS006
5. Install nut and tighten Nut to specified torque.

Installation
1. Align the setting marks(1) made at removal, then
install gear box. 6. Install Pipe and tighten to specified torque.
Steering Gear Disassembled View
440RS001
Legend (7) Seal Ring

(1) Dust Cover (8) O-ring
(2) Retaining Ring (9) Gear Box
(3) Back Up Ring (10) Sector Shaft
(4) Oil Seal (11) Top Cover Assembly
(5) Ball-nut and Valve Housing Assembly (12) Lock Nut
(6) O-ring
Disassembly 6. Remove the top cover bolts and the top cover
assembly.
CAUTION: Do not clamp the steering gear assembly
in a vise by the power cylinder housing.
1. Remove dust cover.
2. Remove retaining ring.
3. Remove back up ring.
4. Remove oil seal.
D Clean the faces of the extended stub shaft.
D Plug the hose fitting on the inlet side.
D Remove the oil seal by blowing compressed air
through the hole in the outlet side.
440RS003
D Holding the top cover stationary, turn the adjusting

screw clockwise to raise and free to cover, then
remove the cover with O-ring.
7. Bring the stub shaft into straight-ahead position. Do
not force the sector shaft off the gear box with a
hammer or other impact tools then remove sector
shaft.
440RS002
5. Remove lock nut.

D Remove the adjusting screw lock nut and turn the
adjusting screw counter-clockwise to remove the
preload between the sector gear and the rack
piston.
440RS004
8. Remove ball-nut and valve housing assembly. Ball-nut Rotation
440RS005
440RS006
D Always keep the ball nut and valve housing Hold the ball nut and valve housing assembly vertically
assembly in a horizontal position to prevent them and see if the ball-nut lowers by turning smoothly. If the
from traveling to the end of the worm shaft and ball-nut does not lower smoothly, check the worm shaft
damaging the ball tubes. for bending and foreign matter.
9. Remove O-ring.
NOTE: When testing the ball nut and valve housing
10. Remove seal ring. assembly, do not let it travel all the way to the end of worm
11. Remove O-ring. shaft, or damage to the ball tubes will result.
12. Remove gear box. D Check sector shaft outside diameter.
Limit: 31.7 mm (1.25 in)
Inspection and Repair
Inspect the following parts for wear, damage or any other
abnormal conditions.
D Bearing
D Ball-nut and valve housing
D Sector shaft
D Top cover
D Gear box
D Needle bearing
D Dust seal
D Seal ring
D Gasket
440RS007
Dust Seal and Seal Ring Setting 3. Apply a thin coat of power steering fluid to the new
seal ring(1) and be sure to discard used part, then
install seal ring.
4. Apply a thin coat of power steering fluid to the new
O-ring and be sure to discard used part, then install
o-ring.
440RW001
D Note the dust seal (1) and the seal ring(2) installation
direction. Always install a new part.
D Apply a thin coat of power steering fluid to lip of each
part.
440RS010
Gasket Setting 5. Install ball-nut and valve housing assembly.

D Always keep the ball screw and valve housing
assembly in a horizontal position (avoid holding it
vertically), or the rack piston will fall off onto the end
of the worm, causing the rack piston to slip out of the
worm shaft and ball to fall out.
440RW002
D Note the gasket(1) installation direction.

D Apply a thin coat of power steering fluid to lip of each
part.
440RS005
Reassembly D Be careful not to drop the O-ring into the valve

housing.
1. Install gear box.
D Tighten the valve housing bolts to the specified
2. Apply a thin coat of power steering fluid to the new torque.
O-ring(2) and be sure to discard used part, then install
o-ring. Torque: 47 N·m (35 lb ft)
6. Install sector shaft. D Lock the sector shaft adjusting screw with the lock
D Tape the sector shaft serrations to protect the seal nut.
ring from damage. Lock nut torque: 41 N·m (30 lb ft)
D Align the center tooth of ball nut with that of the 10. Apply a thin coat of power steering fluid to oil seal lip of
sector shaft. each part, then use installer J–26508 to install oil seal.
440RS004 440RS012
7. Install O-ring. 11. Install back up ring and position the chamfered face
8. Install top cover assembly and tighten the fixing bolts (outer circumference) towards the oil seal.
to specified torque. 12. Install retaining ring and position the chamfered face
Torque: 47 N·m (35 lb ft) (outer circumference) towards the oil seal.
9. Adjust the backlash between the worm gear and the 13. Install dust cover.
ball nut.
440RS011
D With the worm gear rotating, set it to the straight

ahead position.
D Set the worm shaft preload to below 10kg·cm with
the sector shaft adjusting screw.
D Measure the worm shaft preload with the worm
gear turned 450° both to the right and to the left.
The worm gear preload in these positions should be
0.4–0.6 N·m (4–6 kg·cm) lower than in the straight
ahead position.

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

Power Steering Pump and Associated Parts
436RW003
Legend (4) Belt

(1) Hose, Suction (5) Pulley
(2) Hose, Flexible (6) Pump Assembly
(3) Bolt
Removal
2. Place a drain pan below the pump.
3. Remove the air cleaner duct (1) and the radiator
upper hose (2).
436RW004
4. Remove the drive belt.
5. Remove the pulley from the power steering pump.
6. Disconnect the suction hose.
7. Disconnect the flexible hose.
8. Remove the power steering pump fixing bolt.
9. Remove the pump assembly.
CAUTION: When removing the prmp assembly, be
careful not to damage the wiring harnessunder the
pump housing.
Installation
1. Install the adjust plate and tighten the mounting bolts
to the specified torque.
2. Install the pump assembly. Connect the harness
under the pump housing.
3. Tighten the fixing bolt to the specified torque.
4. Connect the flexible hose, then tighten the eye bolt to
specified torque.
5. Connect the suction hose.
6. Install the pulley onto the power steering pump and
tighten the nut to the specified torque.
7. Install the air cleaner duct and the radiator upper
hose.
8. Refill the engine coolant.
9. Fill and bleed the power steering system. Refer to
Bleeding the Power Steering System in this section.
Power Steering Pump Disassembled View
412RX005
Legend (14) Rear Housing Assembly and Pump Cartridge

(1) Bolt (15) Side Plate
(2) Suction Pipe (16) Rotor and Vane
(3) O-ring (17) Pin
(4) Front Housing (18) Cam
(5) Snap Ring (19) Rear Housing
(6) Shaft Assembly (20) Bolt
(7) Bearing (21) Spring
(8) Shaft (22) Retaining Ring
(9) Retaining Ring (23) Filter
(10) Oil Seal (24) Valve
(11) O-ring (25) O-ring
(12) O-ring (26) Connector
(13) Gasket (27) Pressure Switch
Disassembly 7. Remove the valve.

8. Remove the retaining ring.
1. Clean the oil pump with solvent (plug the discharge
and suction ports to prevent the entry of solvent). Be 9. Remove the filter.
careful not to expose the oil seal of shaft assembly to 10. Remove the spring.
solvent. 11. Remove the snap ring.
2. Remove the bolt. 12. Remove the shaft assembly.
3. Remove the suction pipe. 13. Remove the retaining ring.
4. Remove the O-ring. 14. Remove the oil seal.
5. Remove the connector. CAUTION: When removing the oil seal, be careful
6. Remove the O-ring. not to damage the housing.
15. Remove the bolt. Vane
16. Remove the rear housing assembly and the pump
cartridge.
17. Remove the gasket.
18. Remove the O-ring.
19. Remove the O-ring.
20. Remove the front housing.
21. Remove the side plate.
22. Remove the rotor and vane.
23. Remove the cam.
24. Remove the pin.
25. Remove the rear housing.
26. Remove the pressure switch.

Make all necessary adjustments, repairs, and part
replacements if wear, damage, or other problems are
discovered during inspection. 442RS003
Rotor Sliding faces of the vane should be free from wear.

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

Be sure to discard used parts, and always use new parts
for installation. Prior to installation, lubricate all seals and
rings with power steering fluid.
Pressure Switch
Check the switch operation as follows:
With engine idling and A/C on, turn the steering wheel
fully to the left; compressor should interrupt and engine
idle speed will increase. Shut off A/C and again turn
steering fully to the left; engine idle will increase. If system 9. Install a new o-ring and be sure to discard used parts.
fails to function properly, disconnect connector at the 10. Install a new gasket and be sure to discard used
pressure switch and repeat system check while testing parts.
continuity across disconnected SW connector. 11. Install rear housing and pump cartridge.
12. Install bolt and tighten it to the specified torque.
Reassembly Torque: 17.6 N·m (12.8 lb ft)
1. Install rear housing. 13. Install a new oil seal and be sure to discard used
2. Install pin. parts.
3. Install cam. CAUTION: When installing the oil seal, be careful
4. Install the rotor with punch mark facing the front not to damage the oil seal contacting surface of the
housing. housing.
14. Install shaft assembly.
15. Install snap ring.
16. Install spring.
17. Install retaining ring.
18. Install filter.
19. Install valve.
20. Install retaining ring.
21. Install a new o-ring and be sure to discard used parts.
22. Install connector and tighten it to the specified torque.
Torque: 19.6 N·m (14.3 lb ft)
24. Install suction pipe.
25. Install bolt and tighten it to the specified torque.
26. Install pressure switch and tighten it to the specified
torque.
442RS004
5. Install the vanes with curved face in contact with the Torque: 20 N·m (14 lb ft)
inner wall of the cam.
442RS005
6. Install side plate.

CAUTION: When installing side plate, be careful not
to damage its inner surface. Damaged side plate may
cause poor pump performance, pump seizure or oil
leakage.
7. Install front housing.

Oil pump Type Vane
Operating ATF DEXRON–III
fluid
E02RX005
Center Track Rod Assembly

Center Track Rod Assembly and Associated Parts
433RW001
Legend (3) Nut and Cotter Pin, Relay Lever

(1) Nut and Cotter Pin (4) Center Track Rod Assembly
(2) Nut and Cotter Pin, Pitman Arm
Removal 4. Remove nut and cotter pin then use remover J–36831
to remove relay lever from the center track rod.
1. Raise the vehicle and support the frame with suitable
safety stands. CAUTION: Be careful not to damage the ball joint
boot.
2. Remove nut and cotter pin, then use remover
J–36831 to disconnect outer track rod assembly from
the center track rod.
CAUTION: Be careful not to damage the ball joint
boot.
433RS011
5. Remove center track rod assembly.

433RS009 Make necessary correction or parts replacement if wear,
3. Remove nut and cotter pin then use remover J–36831 damage, corrosion, bending, deteriorations or any other
to remove pitman arm from the center track rod. abnormal condition are found through inspection.
Check the ball joint (Boot, screws and tapered surfaces).
boot.
Installation
1. Install center track rod assembly.
2. Install nut, cotter pin and relay lever, then tighten the
nut to the specified torque, with just enough additional
torque to align cotter pin holes. Install new cotter pin.
3. Install nut, cotter pins and pitman arm, then tighten
the nut to the specified torque, with just enough
additional torque to align cotter pin holes. Install new
cotter pin.
4. Install nut and cotter pins, then tighten the nut to the
specified torgue, with fust enough additional torgue to
align cotter pen holes. Install new cotter pin.
433RS010
Outer Track Rod Assembly

Outer Track Rod Assembly and Associated Parts
433RS012
Legend (4) Rod End Assembly, Outer

(1) Rod End Assembly, Inner (5) Nut and Cotter Pin, Knuckle Arm
(2) Lock Nut, Inner (Left-hand threads) (6) Nut and Cotter Pin, Center Track Rod
(3) Lock Nut, Outer
Removal 5. Apply setting marks (1) to ensure reassembly of the

parts in their original position, then remove outer rod
1. Remove wheel and tire assembly. Refer to Wheel end assembly.
Replacement in Suspension section.
2. Remove nut and cotter pin, then use remover
J–36831 to disconnect outer track rod assembly at
the center track rod.
boot.
433RS014
6. Remove inner lock nut.

NOTE: For either outer rod, the screw on the right side of
the vehicle is threaded counterclockwise.
7. Apply setting marks (1) to ensure reassembly of the
parts in their original position, then remove inner rod
433RS009
end.
3. Remove nut and cotter pin then use remover J–36831
to remove outer track rod assembly from the knuckle
arm.
boot.
433RS015

Make necessary correction or parts replacement if wear,
damage, corrosion, bending, deteriorations or any other
433RS013
abnormal condition are found through inspection.
4. Remove outer lock nut.
Check the following parts:
D Rod end assembly
D Ball joint (Boot, screws and tapered surfaces)
Installation
1. Install inner rod end and align the setting marks
applied during disassembly.
2. Tighten the inner lock nut to specified torque.
NOTE: For either outer rod, the screw on the right side of
the vehicle is threaded counterclockwise.
3. Install outer rod end assembly and align the setting
marks applied during disassembly.
4. Tighten the outer lock nut to specified torque.
5. Install knuckle arm nut and cotter pin then tighten the
nut to the specified torque, with just enough additional
torque to align cotter pin holes. Install new cotter pin.
6. Install center track rod and nut and cotter pin then
tighten the nut to the specified torque, with just
enough additional torque to align cotter pin holes.
Install new cotter pin.
NOTE: If replacing the track rod, adjust the new track rod
length.
Rod length: 328.3 mm (12.93 in)
433RS016
NOTE: Adjust the toe-in. Refer to Front End Alignment

Inspection and Adjustment in this section.
Relay Lever
Relay Lever and Associated Parts
433RS017
Legend (4) Relay Lever

(1) Bolt and Nut (5) Nut and Washer
(2) Relay Lever and Bracket (6) Nut and Cotter Pin
(3) Bracket
Removal
safety stands.
2. Remove nut and cotter pin then use remover J–36831
to disconnect relay lever at the center track rod.
433RS011
3. Remove stabilizer bar bolt and nut and push the Installation
stabilizer bar aside, then remove the relay lever bolts
and nuts. 1. Install bracket.
2. Install relay lever.
3. Install nut and washer and tighten the nut to the
specified torque.
4. Install relay lever and bracket.
5. Install bolt and nut and tighten it to the specified
torque.
6. Install nut and cotter pin and tighten the nut to the
specified torque, with just enough additional torque to
align cotter pin holes. Install new cotter pin.
433RS018
4. Remove relay lever and bracket.

5. Remove relay lever nut and washer.
6. Remove relay lever, use remover J–22912–01 to
remove relay lever from the bracket.
433RS019
7. Remove bracket.
Steering Linkage and Associated Parts

E03RS004
Special Tools
TOOL NO.
ILLUSTRATION
TOOL NAME
J–36831
Tie rod end remover
J–22912–01
Relay lever remover
Supplemental Restraint System Steering Wheel & Column

Service Precaution TO AVOID DEPLOYMENT WHEN TROUBLE SHOOT-
ING THE SRS SYSTEM, DO NOT USE ELECTRICAL
This steering wheel and column repair section covers the
TEST EQUIPMENT, SUCH AS BATTERY-POWERED
Supplemental Restraint System (SRS) steering column.
OR A/C-POWERED VOLT-METER, OHMMETER,
The following repair procedures are specific to SRS
components. When servicing a vehicle equipped with ETC., OR ANY TYPE OF ELECTRICAL EQUIPMENT
Supplemental Restraint System, pay close attention to all OTHER THAN SPECIFIED IN THIS MANUAL. DO NOT
WARNINGS and CAUTIONS. USE A NON-POWERED PROBE-TYPE TESTER.
For detailed explanation about SRS, refer to Restraints INSTRUCTIONS IN THIS MANUAL MUST BE FOL-
section. LOWED CAREFULLY, OTHERWISE PERSONAL IN-
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL JURY MAY RESULT.
CAUTION:
COMPONENT AND WIRING LOCATION VIEW IN
ORDER TO DETERMINE WHETHER YOU ARE D Never use the air bag assembly from another
PERFORMING SERVICE ON OR NEAR THE SRS vehicle. Use only the air bag assembly for “UX”.
COMPONENTS OR THE SRS WIRING. WHEN YOU D The driver’s air bag assembly (Inflator module)
ARE PERFORMING SERVICE ON OR NEAR THE SRS for 1999 model has different characteristic to the
COMPONENTS OR THE SRS WIRING, REFER TO parts for 1998 model.
THE SRS SERVICE INFORMATION. FAILURE TO When replace the driver’s air bag assembly,
FOLLOW WARNINGS COULD RESULT IN POSSIBLE confirm the parts number and use only the parts
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR for 1999 model. (The driver’s air bag assembly for
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. 1999 model has “yellow” bar codes label. 1998
model has “white” bar codes label.)
SAFE HANDLING OF INFLATOR MODULES RE-
QUIRES FOLLOWING THE PROCEDURES DE-
SCRIBED BELOW FOR BOTH LIVE AND DEPLOYED
MODULES.
SAFETY PRECAUTIONS MUST BE FOLLOWED
WHEN HANDLING A DEPLOYED AIR BAG AS-
SEMBLY (AIR BAG). AFTER DEPLOYMENT, THE AIR
BAG ASSEMBLY (AIR BAG) SURFACE MAY CON-
TAIN A SMALL AMOUNT OF SODIUM HYDROXIDE, A
BY-PRODUCT OF THE DEPLOYMENT REACTION,
THAT IS IRRITATING TO THE SKIN AND EYES. MOST
OF THE POWDER ON THE AIR BAG ASSEMBLY (AIR
BAG) IS HARMLESS. AS A PRECAUTION, WEAR
GLOVES AND SAFETY GLASSES WHEN HANDLING
A DEPLOYED AIR BAG ASSEMBLY, AND WASH
YOUR HANDS WITH MILD SOAP AND WATER AF-
TERWARDS.
WHEN CARRYING A LIVE AIR BAG ASSEMBLY,
MAKE SURE THE BAG AND TRIM COVER ARE
POINTED AWAY FROM YOU. NEVER CARRY AN AIR 827RX003
BAG ASSEMBLY BY THE WIRES OR CONNECTOR SRS Connectors

ON THE UNDERSIDE OF MODULE. IN THE CASE OF
AN ACCIDENTAL DEPLOYMENT, THE BAG WILL CAUTION: The special tellow color connectors are
used for supplemental restraint system-air bag
THEN DEPLOY WITH MINIMAL CHANCE OF INJURY.
circuit.
WHEN PLACING A LIVE AIR BAG ASSEMBLY ON A
BENCH OR OTHER SURFACE, ALWAYS FACE THE When removing the cable harness, do not pull the
cables. Otherwise, cable disconnection may occur.
BAG AND TRIM COVER UP, AWAY FROM THE SUR-
FACE. When connect the SRS connector, insert the connec-
tor completely. Imperfect locking may cause mal-
NEVER REST A STEERING COLUMN ASSEMBLY function of SRS circuit.
ON THE STEERING WHEEL WITH THE AIR BAG AS-
SEMBLY FACE DOWN AND COLUMN VERTICAL.
THIS IS NECESSARY SO THAT A FREE SPACE IS
PROVIDED TO ALLOW THE AIR BAG ASSEMBLY TO
EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL
DEPLOYMENT. OTHERWISE, PERSONAL INJURY
COULD RESULT.
To remove the connector, hold the cover insulator(1) and To install the connector, hold the soket insulator(1) and
pull it. The cover insulator slides and lock will be released. insert it. The cover insulator slides and connector will be
Do not hold the socket insulator(2). locked.
Do not hold the cover insulator(2).
827RW028
827RW027
Inflator Module
Inflator Module and Associated Parts
827RS048
Legend (2) Inflator Module

(1) Module Connector (3) Fixing Bolt
Removal
1. Turn the steering wheel so that the vehicle’s wheels
are pointing straight ahead.
2. Turn the ignition switch to “LOCK”.
3. Disconnect the battery “–” terminal cable, and wait at
least 5 minutes.
4. Disconnect the yellow 2-way SRS connector located
under the steering column.
5. Loosen the inflator module fixing bolt from behind the
steering wheel assembly using a TORX driver or
equivalent until the inflator module can be released
from steering assembly .
827RT008
6. Disconnect the yellow 2-way SRS connector located D Check for defects such as damage and breakage in
behind the inflator module. the lead wire for the igniter.
If an abnormality is found as the result of the inspection,
replace the inflator module with a new one.
Installation
1. Install inflator module.
CAUTION:
D Never use the air bag assembly from another
vehicle. Use only the air bag assembly for “UX”.
D The driver’s air bag assembly (Inflator module)
for 1999 model has different characteristic to the
parts for 1998 model.
When replace the driver’s air bag assembly,
confirm the parts number and use only the parts
for 1999 model. (The driver’s air bag assembly for
1999 model has “yellow” bar codes label. 1998
2. Support the module and carefully connect the module
827RW002
connector.
7. Remove inflator module. NOTE: Pass the lead wire through the tabs on the plastic
cover (wire protector) of inflator to prevent lead wire from
being pinched.
3. Secure the module with one bolt to relieve weight on
WARNING: THE INFLATOR MODULE SHOULD the wire connector and tighten bolts to specified
ALWAYS BE CARRIED WITH THE URETHANE sequence as illustrated.
COVER AWAY FROM YOUR BODY AND SHOULD
Torque: 8 N·m (69 lb in)
ALWAYS BE LAID ON A FLAT SURFACE WITH THE
URETHANE SIDE UP. THIS IS NECESSARY
BECAUSE A FREE SPACE IS PROVIDED TO ALLOW
THE AIR CUSHION TO EXPAND IN THE UNLIKELY
EVENT OF ACCIDENTAL DEPLOYMENT.
OTHERWISE, PERSONAL INJURY MAY RESULT .
827RW003
4. Connect the yellow 2-way SRS connector located

5. Connect the battery “–” terminal cable.
6. Set ignition to “ON” while watching warning light.
827RS016 Light should flash 7 times and then go off. If lamp
The inflator module consists of a cover, air bag, inflator, does not operate correctly, refer to Restraints section.
and retainer. Inspect the inflator module mainly for the
following:
D Check for holes, cracks, severe blemishes and
deformation on the cover.
D Check that the retainer is not deformed.
Steering Wheel
Steering Wheel and Associated Parts
827RT022
Legend (3) Inflator Module

(1) Horn Lead (4) Steering Wheel
(2) Steering Wheel Fixing Nut
CAUTION: Once the steering column is removed Removal

from the vehicle, the column is extremely
susceptible to damage. Dropping the column 1. Turn the steering wheel so that the vehicle’s wheels
assembly on its end could collapse the steering shaft are pointing straight ahead.
or loosen the slide block which maintains column 2. Turn the ignition switch to “LOCK”.
rigidity. Leaning on the column assembly could 3. Disconnect the battery “–” terminal cable, and wait at
cause the jacket to bend or deform. Any of the above least 5 minutes.
damage could impair the column’s collapsible
design. If it is necessary to remove the steering 4. Disconnect the yellow 2-way SRS connector located
wheel, use only the specified steering wheel puller. under the steering column.
Under no conditions should the end of the shaft be
hammered upon, as hammering could loosen slide
block which maintains column rigidity.
5. Loosen the inflator module fixing bolt from behind the 9. Apply a setting mark (1) across the steering wheel
steering wheel assembly using a TORX driver or and shaft so parts can be reassembled in their original
equivalent until the inflator module can be released position, then remove steering wheel.
from steering assembly.
430RW001
827RT008 10. Move the front wheels to the straight ahead position,
6. Disconnect the yellow 2-way SRS connector located then use steering wheel remover J–29752 to remove
behind the inflator module. the steering wheel.
WARNING: THE INFLATOR MODULE SHOULD CAUTION: Never apply force to the steering wheel
ALWAYS BE CARRIED WITH THE URETHANE in direction of the shaft by using a hammer or other
COVER AWAY FROM YOUR BODY AND SHOULD impact tools in an attempt to remove the steering
ALWAYS BE LAID ON A FLAT SURFACE WITH THE wheel. The steering shaft is designed as an energy
URETHANE SIDE UP. THIS IS NECESSARY absorbing unit.
OTHERWISE, PERSONAL INJURY MAY RESULT.
430RT009
827RS016
7. Disconnect horn lead.

8. Remove steering wheel fixing nut.
Installation 7. Turn the ignition switch to “ON” while watching

warning light. Light should flash 7 times and then go
1. Install steering wheel by aligning the setting marks off. If lamp does not operate correctly, refer to
made when removing. Restraints section.
CAUTION: Never apply force to the steering wheel
in direction of the shaft by using a hammer or other
impact tools in an attempt to remove the steering
wheel. The steering shaft is designed as an energy
absorbing unit.
2. Tighten the steering wheel fixing nut to the specified
torque.
3. Connect horn lead.
connector.
CAUTION:
NOTE: Pass the lead wire through the tabs on the plastic
being pinches.
D Secure the module with one bolt to relieve weight on
the wire connector.
D Tighten bolts to specified sequence as illustrated.
827RW003

Combination Switch
Combination Switch and Associated Parts
431RW001
Legend (4) Combination Switch and SRS Coil Assembly

(1) Steering Column Cover (5) Front Console Assembly
(2) Steering Wheel (6) Steering Lower Cover
(3) Inflator Module (7) Lower Cluster Assembly
Removal CAUTION: The wheels of the vehicle must be

straight ahead and the steering column in the
1. Turn the steering wheel so that the vehicle’s wheels “LOCK” position before disconnecting the steering
are pointing straight ahead. wheel. Failure to do so will cause the coil assembly
2. Turn the ignition switch to “LOCK”. to become uncentered which will cause damage to
3. Disconnect the battery “–” terminal cable, and wait at the coil assembly.
least 5 minutes. 5. Remove the transmission (for M/T) and transfer
4. Disconnect the yellow 2-way SRS connector located control lever knob. Disconnect the wiring harness
under the steering column. connectors then remove front console assembly.
7. Remove the engine hood opening lever, then remove
steering lower cover.
from steering assembly. Disconnect the yellow 2-way
SRS connector located behind the inflator module,
then remove inflator module.
827RS016
9. Apply a setting mark (1) across the steering wheel

and shaft so parts can be reassembled in their original
position. Move the front wheels to the straight ahead
posision, then use steering wheel remover J–29752
to remove the steering wheel.
827RT008
430RW001
827RW002 CAUTION: Never apply force to the steering wheel

WARNING: THE INFLATOR MODULE SHOULD in direction of the shaft by using a hammer or other
ALWAYS BE CARRIED WITH THE URETHANE impact tools in an attempt to remove the steering
COVER AWAY FROM YOUR BODY AND SHOULD wheel. The steering shaft is designed as an energy
ALWAYS BE LAID ON A FLAT SURFACE WITH THE absorbing unit.
CAUTION: When turning the SRS coil
counterclockwise to full, stop turning if resistance is
felt. Forced further turning may damage to the cable
in the SRS coil.
430RT009
10. Remove steering column cover.

11. Disconnect the wiring harness connectors located
under the steering column, then remove combination
switch and SRS coil assembly. 826RW014
NOTE: The SRS coil is a part of the combination switch 2. When installing the steering column cover, be sure to
assembly, which can not be replaced separately. route each wire harness as illustrated so that the
Therefore, be sure not to remove the SRS coil from the harnesses do not catch on any moving parts.
combination switch assembly.
825RW017
825RW030 Legend
(1) Steering Column Cover
Installation (2) Starter Switch Harness
(3) Combination Switch Harness
1. Install combination switch and SRS coil assembly. (4) Inflator Module Harness
After installation of combination switch assembly,
connect the combination switch wiring harness 3. Align the setting marks made when removing then
connector and the SRS 2-way connector located install steering wheel.
under the steering column. Then turn the SRS coil
counterclockwise to full, return about 3 turns and align CAUTION: Never apply force to the steering wheel
the neutral mark. in direction of the shaft by using a hammer or other
absorbing unit.
torque.
5. Support the inflator module and carefully connect the
module connector.
CAUTION:
being pinched.
the wire connector.
7. Tighten bolts to specified sequence as illustrated.
827RW003
8. Install steering lower cover then Install the engine

hood opening lever.
9. Install lower cluster assembly
10. Install the transmission (for M/T) and transfer control
lever knob, then install front console assembly.
11. Connect the wiring harness connectors.
13. Turn the ignition switch to “ON” while watching
warning light and check the light should flash 7 times
and then go off. If lamp does not operate correctly,
refer to Restraints section.
Lock Cylinder
Lock Cylinder and Associated Parts
431RW003
Legend (6) Cushion Rubber

(1) Inflator Module (7) Lock Cylinder Assembly
(2) Steering Wheel (8) Front Console Assembly
(3) Steering Column Cover (9) Lower Cluster Assembly
(4) Combination Switch and SRS Coil Assembly (10) Steering Lower Cover
(5) Snap Ring (11) Shift Lock Cable (for A/T)

1. Turn the steering wheel so that the vehicle’s wheels ”LOCK” position before disconnecting the steering
least 5 minutes. 5. Remove the transmission (for M/T) and transfer
4. Disconnect the yellow 2-way SRS connector located control lever knob and disconnect the wiring harness
under the steering column. connectors, then remove front console assembly.
7. Remove the engine hood opening lever and steering
lower cover.
equivalent until the inflator module can be released position.
430RW001
827RT008 11. Move the front wheels to the straight ahead position,
absorbing unit.
827RW002
430RT009
WARNING: THE INFLATOR MODULE SHOULD 15. Remove snap ring.
ALWAYS BE CARRIED WITH THE URETHANE 16. Remove cushion rubber.
17. Remove shift lock cable (for A/T).
URETHANE SIDE UP. THIS IS NECESSARY 18. Disconnect the starter switch harness connector
BECAUSE A FREE SPACE IS PROVIDED TO ALLOW located under the steering column, then remove lock
THE AIR CUSHION TO EXPAND IN THE UNLIKELY cylinder assembly.
Installation
1. Install lock cylinder assembly.
2. Install shift lock cable (for A/T).
3. Install cushion rubber.
5. Install Combination switch and SRS coil assembly.
connect the combination switch wiring harness
connector and the SRS 2-way connector located
6. Turn the SRS coil counterclockwise to full, return
about 3 turns and align the neutral mark.
in the SRS coil.
827RS016

14. Remove the combination switch assembly with SRS
coil.
NOTE: The SRS coil is a part of the combination switch
assembly, which can not be replaced separately.
Therefore, be sure not to remove the SRS coil from the
826RW014
825RW030
7. When installing the steering column cover, be sure to 12. Tighten fixing bolts to specified sequence as
route each wire harness as illustrated so that the illustrated.
harnesses do not catch on any moving parts. Torque: 8 N·m (69 lb in)
825RW017
827RW003
Legend 13. Install steering lower cover, then install the engine
(1) Steering Column Cover hood opening lever.
(2) Starter Switch Harness 14. Install lower cluster assembly.
(3) Combination Switch Harness 15. Connect the wiring harness connectors, then install
(4) Inflator Module Harness front console assembly and install the transmission
(for M/T) and transfer control lever knob.
8. Install steering wheel by aligning the setting marks 16. Connect the yellow 2-way SRS connector located
made during removal. under the steering column.
CAUTION: Never apply force to the steering wheel 17. Connect the battery “–” terminal cable.
wheel. The steering shaft is designed as an energy System Inspection
absorbing unit. Turn the ignition switch to “ON” while watching warning
9. Tighten the steering wheel fixing nut to the specified light.The light should flash 7 times and then go off. If lamp
torque. does not operate correctly, refer to Restraints section .
10. Support inflator module and carefully connect the
module connector, then install inflator module.
CAUTION:
being pinched.
11. Secure the inflator module with one bolt to relieve
weight on the wire connector.
Steering Column
Steering Column and Associated Parts
431RW002
Legend (7) Lock Cylinder Assembly

(1) Inflator Module (8) Shift Lock Cable (For A/T)
(2) Steering Wheel (9) Steering Column Assembly
(3) Steering Column Cover (10) Front Console Assembly
(4) Combination Switch and SRS Coil Assembly (11) Lower Cluster Assembly
(5) Snap Ring (12) Steering Lower Cover
(6) Cushion Rubber (13) Driver Knee Bolster (reinforcement)
Removal 4. Disconnect the yellow 2-way SRS connector located

least 5 minutes.
CAUTION: The wheel of the vehicle must be straight
ahead and the steering column in the “LOCK”
position before disconnecting the steering column
from the steering gear. Failure to do so will cause the
SRS coil assembly to become uncentered which will
cause damage to the SRS coil assembly.
5. Disconnect the transmission (for M/T) and transfer
control lever knob.
6. Disconnect the wiring harness connectors.
9. Remove the engine hood opening lever, then remove
steering lower cover.
10. Remove driver knee bolster (reinforcement).
827RS016

position, then use steering wheel remover J–29752 to
remove the steering wheel.
827RT008

behind the inflator module.
13. Remove inflator module.
WARNING: THE INFLATOR MODULE SHOULD
ALWAYS BE CARRIED WITH THE URETHANE 430RW001

22. Apply a setting mark (1) across the universal joint and
steering shaft to reassemble the parts in their original
position, then remove steering column assembly.
NOTE: A setting mark can be easily made if the shaft is
withdrawn a little by loosening the steering shaft universal
joint.
430RT009

coil.
NOTE: SRS coil is a part of combination switch 431RW004
assembly, which can not be replaced singly. Therefore,

be sure not to remove the SRS coil from the combination Inspection
switch assembly.
If the abnormal conditions are found through inspection,
replace the steering column assembly.
Column Capsule
Check capsules on steering column bracket assembly; all
must be securely seated in bracket slots and checked for
any loose conditions when pushed or pulled by hand.
825RW030
18. Remove snap ring.

19. Remove cushion rubber.
20. Remove shift lock cable (For A/T).
21. Disconnect the starter switch harness connector
located under the steering column, then remove lock
431RW030
cylinder assembly.
Check clearance between capsule and bracket. It must Sheared Injected Plastic Pin
be within 1 mm (0.039 in). Check the sheared injected plastic pins for any loose
conditions or damage.
431RW031
Column Tube 431RW033
Check for collapse by measuring the distance as shown in Shaft Length

the figure. Check the shaft length from the upper end of the slide joint
Standard distance: 162.2–165.8 mm (6.386–6.528 to the end of the shaft. If column length is not in
in) specifications, steering column should be replaced.
Standard length: 308–310 mm (12.126–12.205 in)
431RW032
Column Universal Joint for Tilt Mechanism 431RX003
If the resistance is felt when checked by rotate the joint, Shaft Universal Joint (Lower End)
replace the steering column assembly. If the resistance is felt when checked by rotate the joint,
Shaft Bellows Pipe

Check the shaft bellows pipe for bend by using straight
edge. Measure the clearance between the bellows pipe
and the straight edge (at center of the bellows pipe).
Standard: Less than 1 mm (0.039 in)
431RW035 826RW014
12. When installing the steering column cover, be sure to

Tilt Mechanism route each wire harness as illustrated so that the
Tilt mechanism should moves smoothly. harnesses do not catch any moving parts.
While locked the tilt mechanism, be sure the steering
column latch securely by pushing the steering wheel
upward and downward.
Installation
1. Install steering column assembly.
2. Align the setting marks on the universal joint and
steering shaft made during removal.
3. Tighten the steering column fixing bolt (dash panel) to
4. Tighten the steering column fixing bolt (pedal
bracket) to the specified torque.
5. Tighten the universal joint to the specified torque.
6. Install lock cylinder assembly. 825RW017
7. Install shift lock cable (For A/T). Legend

8. Install cushion rubber. (1) Steering Column Cover
9. Install snap ring. (2) Starter Switch Harness
After installation of combination switch assembly, (4) Inflator Module Harness
connector and the SRS 2-way connector located 13. Install steering wheel and align the setting marks
under the steering column. made when removing.
11. Turn the SRS coil counterclockwise to full, return CAUTION: Never apply force to the steering wheel
about 3 turns and align the neutral mark. in direction of the shaft by using a hammer or other
CAUTION: When turning the SRS coil wheel. The steering shaft is designed as an energy
counterclockwise to full, stop turning if resistance is absorbing unit.
in the SRS coil. 14. Tighten the steering wheel fixing nut to the specified
torque.
connector then install inflator module.
CAUTION:
being pinched.
the wire connector.
17. Tighten bolts to specified sequence as illustrated.
827RW003
18. Install driver knee bolster (reinforcement).

19. Install steering lower cover.
20. Install the engine hood opening lever.
21. Install lower cluster assembly.
22. Connect the wiring harness connectors then install
front console assembly.
23. Install the transmission (for M/T) and transfer control
lever knob.
System Inspection
Turn the ignition switch “ON” while watching warning light.
The light should flash 7 times and then go off. If lamp does
not operate correctly, refer to Restraints section.
Supplemental Restraint System Steering Wheel & Column and

Associated Parts
E03RW001
Special Tools
TOOL NO.
ILLUSTRATION
TOOL NAME
J–29752
Steering wheel remover
FRONT SUSPENSION 3C-1
TROOPER
SUSPENSION
CONTENTS
Front Suspension . . . . . . . . . . . . . . . . . . . . . . . 3C
Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . 3D
Wheel and Tire System . . . . . . . . . . . . . . . . . . 3E
FRONT SUSPENSION
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 3C–1 Upper Control Arm . . . . . . . . . . . . . . . . . . . . . . 3C–14
General Description . . . . . . . . . . . . . . . . . . . . . 3C–2 Upper Control Arm and Associated Parts . 3C–14
General Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 3C–3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C–14
Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . 3C–6 Inspection and Repair . . . . . . . . . . . . . . . . . . 3C–15
Shock Absorber and Associated Parts . . . . 3C–6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C–16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C–6 Lower Control Arm . . . . . . . . . . . . . . . . . . . . . . 3C–18
Inspection and Repair . . . . . . . . . . . . . . . . . . 3C–6 Lower Control Arm and Associated Parts . 3C–18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C–6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C–18
Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C–7 Inspection and Repair . . . . . . . . . . . . . . . . . . 3C–20
Stabilizer Bar and Associated Parts . . . . . . 3C–7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C–20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C–7 Upper Ball Joint . . . . . . . . . . . . . . . . . . . . . . . . . 3C–22
Inspection and Repair . . . . . . . . . . . . . . . . . . 3C–7 Upper Ball Joint and Associated Parts . . . . 3C–22
Torsion Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C–8 Inspection and Repair . . . . . . . . . . . . . . . . . . 3C–23
Torsion Bar and Associated Parts . . . . . . . . 3C–8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C–23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C–8 Lower Ball Joint . . . . . . . . . . . . . . . . . . . . . . . . . 3C–24
Inspection and Repair . . . . . . . . . . . . . . . . . . 3C–9 Lower Ball Joint and Associated Parts . . . . 3C–24
Knuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C–11 Inspection and Repair . . . . . . . . . . . . . . . . . . 3C–25
Knuckle and Associated Parts . . . . . . . . . . . 3C–11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C–25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C–11 Main Data and Specifications . . . . . . . . . . . . . 3C–26
Inspection and Repair . . . . . . . . . . . . . . . . . . 3C–12 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C–27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C–12

FOLLOW WARNING COULD RESULT IN POSSIBLE clamping force, and may damage the fastener. When
systems.
3C-2 FRONT SUSPENSION
General Description
C03RW001
Legend (4) Torsion Bar

(1) Shock Absorber (5) Link
(2) Upper Control Arm (6) Lower Control Arm
(3) Height Control Arm (7) Stabilizer Bar
The front suspension is designed to allow each wheel to into a height control arm at the crossmember. Vehicle trim
compensate for changes in the road surface level without height is controlled by adjusting this arm.
greatly affecting the opposite wheel. Each wheel is Shock absorbers are mounted between the brackets on
independently connected to the frame by a steering the frame and the lower control arms. The lower portion of
knuckle, ball joint assemblies, and upper and lower each shock absorber is attached to the lower control arm.
control arms. The front wheels are held in proper The upper portion of each shock absorber extends
relationship to each other by two outer track rods which through a frame bracket and is secured with two rubber
are connected to steering arms on the knuckles, and to a bushings, three retainers and a nut.
center track rod. Ball joint assemblies are bolted to the outer end of the
All models have a front suspension system consisting of upper and lower control arm and are attached to the
control arms, stabilizer bar, shock absorber and a torsion steering knuckle.
bar. The front end of the torsion bar is attached to the The inner ends of the upper control arm have pressed in
lower control arm. The rear of the torsion bar is mounted bushings. Bolts, passing through the bushing, attach the
control arm to the frame. The inner ends of the lower
FRONT SUSPENSION
control arm are attached to the frame by bolts passing which are held to the crossmember by brackets. The ends
through the bushings, which are pressed in the frame. of the stabilizer bar are connected to the lower control
Side roll of the front suspension is controlled by a spring arms by links.
steel stabilizer bar. It is mounted in rubber bushings,
General Diagnosis
wheel.
Loose steering gear. Tighten housing bolts.

Steering gear misadjustment. Check and adjust pinion torque.
Improper power steering system Repair or replace. Refer to Steering
operation. section.
Loose steering gear or linkage. Retighten or repair.
Steering gear misadjustment. Inspect and adjust steering gear
preload.
universal joint.
bushing.
wheel nut holes. Replace wheel if
required.
bearings.
Loose steering gear. Retighten mounting bolt.
Faulty steering gear. Check and adjust steering gear.
pressure.
bushings.
Steering gear misadjustment. Check or adjust steering gear.
Low or Uneven Trim Height Broken or sagging springs. Replace springs (In pairs).
Vehicle overloaded. Reduce load.
Incorrect springs. Adjust or replace torsion bar.
Suspension Bottoms Vehicle overloaded. Reduce load.
Incorrect, broken or sagging springs. Replace springs.
Body Leans Loose stabilizer bar. Tighten stabilizer bar bolts or replace
bushings.
Faulty shock absorber, struts or Replace shock absorber.
mounting.
Broken or sagging springs. Replace springs (In pairs).
Cupped Tires Worn wheel bearings. Replace wheel bearing.
Excessive tire or wheel run out. Replace tire or wheel.
Worn ball joints. Replace ball joints.
Tire out of balance. Adjust tire balance.
Shock Absorber
Shock Absorber and Associated Parts
450RS006
Legend (3) Bolt, Nut and Washer

(1) Nut (4) Shock Absorber
(2) Rubber Bushing and Washer (5) Rubber Bushing and Washer
1. Raise the vehicle and support it with suitable safety 1. Install rubber bushing and washer.
stands. 2. Install shock absorber.
2. Remove wheel and tire assembly. Refer to Wheel 3. Install rubber bushing and washer.
Replacement in this section.
4. Install nut, then tighten it to the specified torque.
3. Remove bolt,nut and washer.
4. Remove nut.
5. Install bolt, nut and washer, then tighten to the
5. Remove rubber bushing and washer.
specified torque.
6. Remove shock absorber.

damage, corrosion or any other abnormal conditions are
found through inspection.
D Shock absorber
D Rubber bushing
Stabilizer Bar
Stabilizer Bar and Associated Parts
410RS002
Legend (3) Bracket

(1) Nut and Washer (4) Rubber Bushing
(2) Link (5) Stabilizer Bar
Removal Inspection and Repair

1. Raise the vehicle and support the frame with suitable Make necessary correction or parts replacement if wear,
safety stands. damage, corrosion or any other abnormal conditions are
3. Remove wheel and tire assembly. Refer to Wheel D Stabilizer bar
D Rubber bushing
4. Remove nut and washer.
D Link ball joint
CAUTION: Be careful not to break the ball joint boot.
5. Remove link.
Installation
6. Remove bracket. 1. Install rubber bushing.
7. Remove stabilizer bar. 2. Install stabilizer bar.
8. Remove rubber bushing. 3. Install bracket, then tighten it to the specified torque.
4. Install link.
5. Install nut and washer, then tighten the nut to the
specified torque.
Torsion Bar
Torsion Bar and Associated Parts
410RS003
Legend (2) Height Control Arm

(1) Adjust Bolt, End Piece and Seat (3) Torsion Bar
Removal
safety stands.
2. Apply the setting marks(1) to the adjust bolt and end
piece, then remove adjust bolt, end piece and seat.
410RS004
3. Apply the setting marks(2) to the height control arm D Height control arm
and torsion bar, then remove height control arm. D Adjust bolt
D Rubber seat
Installation
1. Apply grease to the serrated portions, then install
torsion bar. Make sure the bars are on their correct
respective sides and align the setting marks(3).
410RS005
4. Apply the setting marks(3) to the torsion bar and

lower control arm, then remove torsion bar.
410RS007
410RS006

found through inspection. 410RS006

D Torsion bar
2. Apply grease to the portion that fits into the bracket 5. Install adjust bolt and seat, then turn the adjust bolt to
then install height control arm and align the setting the setting mark(1) applied during disassembly.
marks(2).
NOTE: Adjust the trim height. Refer to Front End
Alignment Inspection and Adjustment in Steering section.
410RS005
3. Apply grease to the bolt portion of the end piece(4).

Apply grease to the portion of the seat(5) that fits into 410RS004
the bracket.
410RS008
4. Apply grease to the serrated portions.

Knuckle
Knuckle and Associated Parts
410RW001
Legend (6) Needle Bearing

(1) Torsion Bar (7) Thrust Washer
(2) Lower Ball Joint (8) Oil Seal
(3) Back Plate (9) Upper Ball Joint
(4) Knuckle Assembly (10) Wheel Speed Sensor
(5) Knuckle
Removal 4. Remove the hub assembly. Refer to Front Hub and

Disk in Driveline/Axle section.
1. Raise the vehicle and support the frame with suitable 5. Remove outer track rod from the knuckle. Refer to
safety stands. Outer Track Rod Assembly Replacement in Steering
2. Remove wheel and tire assembly. Refer to Wheel section.
Replacement in this section. 6. Remove the speed sensor from the knuckle.
3. Remove the brake caliper. Refer to Disc Brakes in 7. Loosen torsion bar by height control arm adjust bolt,
Brake section. then remove torsion bar. Refer to Torsion Bar
8. Remove wheel speed sensor. 15. Remove needle bearing by using remover J–23907.
9. Remove back plate.
10. Remove lower ball joint by using remover J–29107.
boot.
901RW044

901RW042
11. Remove upper ball joint by using remover J–36831. found through inspection.
CAUTION: Be careful not to damage the ball joint D Knuckle
boot.
D Knuckle arm
D Needle bearing
D Thrust washer
Installation
1. Apply appropriate amount of multipurpose type
grease to the new bearing (Approx. 5 g)and install
needle bearing by using installer J–36838 and
J–8092.
901RW043
12. Remove knuckle assembly.

13. Remove oil seal.
14. Remove washer.
901RW045
2. Apply multipurpose type grease to the thrust washer,
and install washer with chamfered side facing
knuckle.
3. Use a new oil seal, and apply multipurpose type
grease to the area surrounded by the lip (approx. 2 g).
Then use installer J–41468 and J–8092 to install oil
seal. After fitting the oil seal to the installer, drive it to
the knuckle using a hammer or bench press until the
tool front face contacts with the thrust washer.
901RW046
4. Install knuckle assembly.

5. Install upper ball joint and tighten the nut to the
6. Install lower ball joint and tighten the nut to the
7. Install back plate.
8. Install wheel speed sensor.
9. Install torsion bar, refer to Torsion Bar Replacement in
this section.
Alignment Inspection and Adjustment in Steering
section.
Upper Control Arm

Upper Control Arm and Associated Parts
450RS007
Legend (7) Bushing

(1) Bolt and Plate (8) Plate
(2) Camber Shims (9) Nut
(3) Caster Shims (10) Speed Sensor Cable
(4) Nut Assembly (11) Nut and Cotter Pin
(5) Upper Control Arm Assembly (12) Upper Ball Joint
(6) Fulcrum Pin
Removal 3. Remove the brake caliper and disconnect brake pipe.

Refer to Disc Brakes in Brake section.
1. Raise the vehicle and support the frame with suitable 4. Support lower control arm with a jack.
safety stands.
5. Remove speed sensor cable.
2. Remove wheel and tire assembly. Refer to Wheel
Replacement in this section. 6. Remove nut and cotter pin then use remover
J–36831.
901RW048
901RW043
16. Remove fulcrum pin.
7. Remove upper ball joint.
8. Remove bolt and plate. Inspection and Repair
9. Remove nut assembly. Make necessary parts replacement if wear, damage,
10. Remove camber shims and note the positions and corrosion or any other abnormal conditions are found
number of shims. through inspection.
11. Remove caster shims and note the positions and Check the following parts:
number of shims. D Upper control arm
12. Remove upper control arm assembly. D Bushing
13. Remove nut. D Fulcrum pin
14. Remove plate.
15. Remove bushing by using remover J–29755.
901RW047
Installation
1. Install fulcrum pin.
2. Install bushing by using installer J–29755 and
J–39376.
450RS012
5. Install upper control arm assembly with the fulcrum

pin projections turned inward.
901RW049
450RS013
Legend
(1) Projection
901RW050
(2) Outward
3. Install plate.
4. Install nut and tighten fulcrum pin nut finger–tight. 6. Install the caster shims(2) between the chassis frame
NOTE: Torque fulcrum pin nut after adjusting buffer and fulcrum pin.
clearance.
Buffer clearance: 20 mm (0.79 in)
7. Install the camber shims(1) between the chassis
frame and fulcrum pin.
450RS014
8. Install nut assembly.

9. Install bolt and plate, then tighten the bolt to the
specified torque.
10. Install upper ball joint and tighten it to the specified
torque.
11. Install nut and cotter pin then tighten the nut to the
12. Install speed sensor cable.
Lower Control Arm

Lower Control Arm and Associated Parts
450RS015
Legend (8) Bolt, Torsion Bar Arm

(1) Nut and Washer, Front (9) Torsion Bar Arm Bracket
(2) Bush, Front (10) Torsion Bar
(3) Bolt, Front (11) Lower Control Arm
(4) Nut and Washer, Rear (12) Lower Ball Joint
(5) Bush, Rear (13) Shock Absorber
(6) Bolt, Rear (14) Stabilizer Link
(7) Bolt, Lower Ball Joint
Removal 3. Remove the outer track rod from the knuckle. Refer to
Steering Linkage in Steering section.
1. Raise the vehicle and support the frame with suitable 4. Remove the retaining ring from the front axle driving
safety stands. shaft to release the shaft from hub. Refer to Front Hub
2. Remove wheel and tire assembly. Refer to Wheel and Disc in Driveline/Axle section.
Replacement in this section. 5. Support lower control arm with a jack.
6. Remove front nut and washer.
7. Remove rear nut and washer.
8. Remove torsion bar, refer to Torsion Bar
9. Remove torsion bar arm bracket.
10. Disconnect the stabilizer link at the lower control arm.
11. Remove the shock absorber lower end from the lower
control arm.
12. Remove the lower ball joint from the lower control
arm.
13. Remove front bolt.
14. Remove rear bolt.
15. Remove lower control arm.
16. Remove torsion bar arm bolt.
17. Remove lower ball joint bolt.
18. Remove front bushing by using remover J–36833.
901RW035
19. Remove rear bushing by using remover J–36834.
901RW034
901RW051
2. Install front bushing by using installer J–36833.
901RW052
901RW036
Inspection and Repair 3. Install lower ball joint bolt.

Make necessary correction or parts replacement if wear, 4. Install torsion bar arm bolt.
damage, corrosion or any other abnormal conditions are 5. Install lower control arm.
found through inspection. 6. Install rear bolt.
7. Install front bolt.
D Lower control arm
8. Install lower ball joint and tighten it to the specified
D Bushing
torque.
Installation 9. Install shock absorber and tighten it to the specified
1. Install rear bushing by using installer J–36834. torque.
10. Install stabilizer link and tighten it to the specified
torque.
11. Install torsion bar arm bracket and tighten it to the
specified torque.
12. Install Torsion bar, refer to Torsion Bar Replacement
in this section.
901RW053
13. Install rear nut and washer and tighten lower link nut
finger–tight.
NOTE: Torque lower control arm nut after adjusting buffer
clearance.
450RS012
14. Install front nut and washer then tighten lower link nut
finger-tight.
clearance .
450RS012
Upper Ball Joint

Upper Ball Joint and Associated Parts
450RS022
Legend (2) Upper Ball Joint

(1) Bolt, Nut and Washer (3) Nut and Cotter Pin
Removal
safety stands.
2. Remove the speed sensor from the knuckle.
3. Remove upper ball joint nut and cotter pin, then use D After moving the ball joint 4 or 5 times, attach nut then
remover J–36831 to remove the upper ball joint from measure the preload.
the knuckle. Starting torque: 0.5 –3.2 N·m (0.4–2.4 lb ft)
450RS024
901RW043 If the above limits specified are exceeded, replace the ball
4. Remove bolt and washer. joint assembly.
5. Remove upper ball joint.
Installation
Inspection and Repair 1. Install upper ball joint.
Make necessary parts replacement if wear, damage, 2. Install bolt and nut, then tighten them to the specified
corrosion or any other abnormal conditions are found torque.
through inspection. Torque: 57 N·m (42 lb ft)
D Inspect the lower end boot for damage or grease leak.
Move the ball joint as shown in the figure to confirm its 3. Install nut and cotter pin, then tighten the nut to the
normal movement. specified torque with just enough additional torque to
D Inspect screw/taper area of ball for damage.
D If any defects are found by the above inspections,
replace the ball joint assembly with new one.
450RS023
Lower Ball Joint

Lower Ball Joint and Associated Parts
450RS025
Legend (3) Nut

(1) Bolt (4) Nut and Cotter Pin
(2) Lower Ball Joint
Removal
safety stands.
2. Remove wheel and tire assembly. Refer to Wheel
3. Remove the outer track rod from the knuckle. Refer to
4. Remove the retaining ring from the front axle driving
shaft to release the shaft from hub. Refer to Front Hub
and Disc in Driveline/Axle section.
5. Support lower control arm with a jack.
6. Remove lower ball joint nut and cotter pin, then use
remover J–29107 to remove the lower ball joint from
the knuckle.
boot.
901RW042
7. Remove nut. Installation
8. Remove lower ball joint.
1. Install bolt.
9. Remove bolt.
2. Install lower ball joint.
3. Install nut and tighten it to the specified torque.
Inspection and Repair Torque: 103 N·m (76 lb ft)
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal conditions are found 4. Install nut, then tighten it to the specified torque with
through inspection. just enough additional torque to align cotter pin holes.
Install new cotter pin.
Move the ball joint as shown in the figure to confirm its Torque: 147 N·m (108 lb ft)
normal movement .
450RS026
D After moving the ball joint 4 or 5 times, attach nut the

measure the preload.
Starting torque: 0.5–6.4 N·m (0.4–4.7 lb ft)
450RS024
D If the above limits specified are exceeded, replace the

ball joint assembly.

Front suspension Type Independent wishbone arms, torsion bar spring
with stabilizer bar.
Torsion bar spring Length 1217 mm (47.9 in)
Diameter 26.6 mm (1.05 in)
Front shock absorber Type Hydraulic, double acting, telescopic
Piston diameter 30.0 mm (1.18 in)
Stroke 130.0 mm (5.12 in)
Compressed length 390.0 mm (15.35 in)
Extended length 260.0 mm (10.24 in)
Stabilizer bar Diameter 26.0 mm (1.02 in)
E03RS005
Special Tools
TOOL NO. TOOL NO.
TOOL NAME TOOL NAME
J–36833
J–23907
Remover and Installer
Remover; Needle
kit;
bearing
Lower arm front bushing
J–36834
J–36838 Remover and Installer
Installer; Needle bearing kit;
Lower arm rear bushing
J–8092 J–36831
Grip Tie rod end remover
J–41468 J–29107
Installer; Oil seal Lower end remover
J–39376
Installer; Upper arm
bushing
J–29755
Upper arm bushing
REAR SUSPENSION 3D–1
TROOPER
SUSPENSION
REAR SUSPENSION
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 3D–1 Center Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–8
General Description . . . . . . . . . . . . . . . . . . . . . 3D–2 Center Link and Associated Parts . . . . . . . . 3D–8
Coil Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–8
Coil Spring and Associated Parts . . . . . . . . 3D–3 Inspection and Repair . . . . . . . . . . . . . . . . . . 3D–8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–9
Inspection and Repair . . . . . . . . . . . . . . . . . . 3D–4 Lateral Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–4 Lateral Rod and Associated Parts . . . . . . . 3D–10
Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . 3D–5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–10
Shock Absorber and Associated Parts . . . . 3D–5 Inspection and Repair . . . . . . . . . . . . . . . . . . 3D–10
Inspection and Repair . . . . . . . . . . . . . . . . . . 3D–5 Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–5 Stabilizer Bar and Associated Parts . . . . . . 3D–12
Trailing Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–12
Trailing Link and Associated Parts . . . . . . . 3D–6 Inspection and Repair . . . . . . . . . . . . . . . . . . 3D–12
Inspection and Repair . . . . . . . . . . . . . . . . . . 3D–6 Main Data and Specifications . . . . . . . . . . . . . 3D–14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–7 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–16
Service Precaution
ORDER TO DETERMINE WHETHER YOU ARE
PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING. WHEN YOU
ARE PERFORMING SERVICE ON OR NEAR THE SRS
COMPONENTS OR THE SRS WIRING, REFER TO
THE SRS SERVICE INFORMATION. FAILURE TO
FOLLOW WARNINGS COULD RESULT IN POSSIBLE
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR
use supplemental coatings (Paints, greases, or other
corrosion inhibitors) on threaded fasteners or
fastener joint interfaces. Generally, such coatings
adversely affect the fastener torque and the joint
clamping force, and may damage the fastener. When
you install fasteners, use the correct tightening
sequence and specifications. Following these
systems.
3D–2 REAR SUSPENSION
General Description
C03RS003
Legend (3) Shock Absorber

(1) Stabilizer Bar (4) Trailing Link
(2) Lateral Rod (5) Center Link
The rear suspension is a 4-link, coil spring type

suspension with a stabilizer bar, consisting of two trailing
links, center link, lateral rod, shock absorber, and
stabilizer. In this suspension, the links are specially
arranged to enable the rear axle to move freely, thereby
expanding suspension stroke, reducing friction, and
improving lateral rigidity and roll control. All these result in
improved stability, riding comfort, and rough road
maneuverability.
Each link connects the axle housing with the frame
through a runner bushing. The axle housing is supported
by the trailing links and center link longitudinally and by
the lateral rod latitudinally.
Coil Spring
Coil Spring and Associated Parts
460RS001
Legend (3) Coil Spring

(1) Parking Brake Cable Bracket (4) Insulator
(2) Shock Absorber (5) Stabilizer Bar
Removal 6. Remove spring insulator.

7. Remove the lower insulator and coil spring while
1. Raise the vehicle and support the frame with suitable lowering the rear axle case.
safety stands.
2. Support the rear axle case with a jack. CAUTION: Be sure not to let the brake hose, parking
brake cable, and breather hose extend to their full
3. Remove the parking brake cable bracket from the length.
trailing link.
4. Disconnect the stabilizer bar at the stabilizer link.
5. Remove the shock absorber from the axle case.

D Coil spring
D Insulator
Installation
1. Install coil spring and make sure that the coil spring is
installed in the proper position. Paint mark(1) should
be downward.
460RS004
4. Install shock absorber and tighten the nut lightly,then

retighten it to the specified torque after the vehicle is
at curb height.
NOTE: When mounting shock absorber, be sure not to
use grease on bushings or any other nearby part.
5. Install stabilizer bar.
6. Install parking brake cable bracket.
460RW001
2. Fit the end of the coil spring to the coil spring seat and
mount the coil spring on the rear axle case.
460RS003
3. Install the insulator on the coil spring. Jack up the axle

case gently with the top of the coil spring set to the
spring seat on the frame side.
Shock Absorber
461RW002

(1) Bolt and Nut (3) Nut and Washer
Removal 2. Install bolt and nut, then tighten the bolt and nut lightly.
Retighten to the bolt and nut specified torque after the
1. Remove shock absorber fixing nut and washer. vehicle is at curb height.
2. Remove shock absorber fixing bolt and nut. Torque: 95 N·m (70 lb ft)
3. Remove shock absorber. 3. Install nut and washer, then tighten the nut lightly.
Retighten to the nut specified torque after the vehicle
Inspection and Repair is at curb height.
Make necessary correction or parts replacement if wear, Torque: 78 N·m (58 lb ft)
D Shock absorber
D Rubber bushing (Axle side)
NOTE: When mounting rubber bushings, be sure not to
Installation
1. Install shock absorber. When mounting shock
absorber, be sure not to use grease on bushings or
any other nearby part.
Trailing Link
Trailing Link and Associated Parts
460RW017
Legend (2) Bolt and Nut

(1) Parking Brake Cable (3) Trailing Link
Removal
1. Remove the parking brake cable from the trailing link.
2. Remove the trailing link fixing bolt and nut.
3. Remove trailing link.

1. Trailing link
2. Rubber bushing
D Remove the rubber bushing by using remover
J–39214.
901RW058
D Install the rubber bushing by using installer
J–39214.
901RW059
Installation
1. Install trailing link. Make sure that the trailing link is in
its correct position.
NOTE: When mounting trailing link, be sure not to use
grease on bushings or any other nearby part.
460RS008
2. Install bolt and nut. Tighten the bolts and nuts lightly,
then retighten them to the specified torque after the
vehicle is at curb height.
3. Install parking brake cable.
CAUTION: The parking brake cable should not be
overstrained or slackened.
Center Link
Center Link and Associated Parts
460RX001
Legend (3) Speed Sensor Cable Bracket

(1) Center Link (4) Speed Sensor Cable
(2) Bolt and Nut
Removal
1. Remove the speed sensor cable from the center link.
2. Remove the speed sensor cable bracket from the
frame.
3. Remove bolt and nut.
4. Remove center link.

1. Center link
2. Rubber bushing
J–39214.
901RW058
D Install the rubber bushing by using to installer
J–39214.
901RW059
Installation
1. Install center link. Make sure that the center link is in
NOTE: When mounting center link, be sure not to use
grease bushings or any other nearby part.
460RS010
2. Install bolt and nut. Tighten the bolts and nuts lightly,
3. Install speed sensor cable bracket.
Lateral Rod
Lateral Rod and Associated Parts
460RW019
Legend (2) Nut and Washer

(1) Bolt and Nut (3) Lateral Rod
Removal
3. Remove lateral rod.

damage, corrosion or any other abnormal condition are
1. Lateral rod
2. Rubber bushing (Frame side)
D Remove the rubber bushing (Frame side) by using
remover J–39214.
901RW060
D Install the rubber bushing (Frame side) by using
Installer J–39215.
NOTE: When mounting rubber bushings, do not use
grease on bushings or any other nearby parts.
901RW063
Installation
1. Install lateral rod and make sure that the lateral rod is
901RW061 in its correct position.
3. Rubber bushing (Axle side) NOTE: When mounting lateral rod, be sure not to use
D Remove the rubber bushing (Axle side) by using grease on bushings or any other nearby part.
remover J–39792.
460RS016
901RW062
Legend
D Install the rubber bushing (Axle side) by using
installer J–39792. (1) Frame Side
(2) Axle Side
2. Install bolt and nut. Tighten the bolt and nut lightly,
3. Install nut and washer. Tighten the nut lightly, then
retighten the nut to the specified torque after the
Stabilizer Bar
460RW020
Legend (3) Bracket

(1) Nut and Washer (4) Rubber Bushing
(2) Link (5) Stabilizer Bar
Removal 6. Remove rubber bushing.

7. Remove stabilizer bar.
safety stands.
2. Remove wheel and tire assembly. Refer to Wheel Inspection and Repair
Replacement in this section. Make necessary correction or parts replacement if wear,
3. Remove nut and washer. damage, corrosion or any other abnormal conditions are
4. Remove link. found through inspection.
CAUTION: Be careful not to damage the ball joint D Stabilizer bar
boot.
D Rubber bushing
5. Remove bracket.
D Link ball joint
Installation
2. Install rubber bushing.
3. Install bracket and tighten to the specified torque.
4. Install link.
5. Install nut and washer, then tighten the nut to the
specified torque.
460RS018

Rear suspension Type 4–Link, coil spring type with stabilizer bar.
Coil spring Free length 402mm (15.83in)
Spring diameter 12.7mm (0.5in)
Coil diameter (inner) 105mm (4.13in)
Effective No. of turns 5.32
Total No. of turns 6.82
Shock absorber Type Hydraulic, double acting, telescopic
Piston diameter 25.0mm (0.98in)
Stroke 175mm (6.89in)
Extended length 489mm (19.25in)
Compressed length 314mm (12.36in)
Stabilizer bar Diameter 19.0mm (0.75in)
E03RW006
Special Tools
TOOL NO.
ILLUSTRATION
TOOL NAME
J–39214
Remover and Installer;
Trailing center link
bushing
J–39792
Lateral rod bushing (axle
side)
J–39215
Lateral rod bushing
WHEEL AND TIRE SYSTEM 3E–1
TROOPER
SUSPENSION
WHEEL AND TIRE SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 3E–1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E–9
General Description . . . . . . . . . . . . . . . . . . . . . 3E–2 Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E–10
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E–3 Tire Replacement . . . . . . . . . . . . . . . . . . . . . . 3E–10
Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E–9 General Balance Procedure . . . . . . . . . . . . . . 3E–10
Wheel and Associated Parts . . . . . . . . . . . . 3E–9 Balancing Wheel and Tire . . . . . . . . . . . . . . . . 3E–11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E–9 Main Data and Specifications . . . . . . . . . . . . . 3E–12
Service Precaution
FOLLOW WARNING COULD RESULT IN POSSIBLE
systems.
3E–2 WHEEL AND TIRE SYSTEM
General Description
480RS008
Replacement wheels or tires must be equivalent to the metric sized tubeless steel belted radial tires. Correct tire
originals in load capacity, specified dimension and pressures and driving habits have an important influence
mounting configuration. Improper size or type may affect on tire life. Heavy cornering, excessively rapid
bearing life, brake performance, speedometer/odometer acceleration and unnecessary sharp braking increase
calibration, vehicle ground clearance and tire clearance premature and uneven wear.
to the body and chassis. All model are equipped with
Diagnosis
480RS001
Irregular and Premature Wear If the following conditions are noted, rotate the tires:
Irregular and/or premature wear has many causes. D Front tire wear is different from rear.
Some of them are incorrect inflation pressures, lack of tire D Uneven wear exists across the tread of any tire.
rotation, poor driving habits or improper wheel alignment. D Left and right front tire wear is unequal.
Incorrect inflation is common cause of tire premature D Left and right rear tire wear is unequal.
wear.
Check wheel alignment if the following conditions are
NOTE: Due to their design, radial tires tend to wear faster noted:
in the shoulder area, particularly on the front tires. This D Left and right front tire wear is unequal.
makes regular rotation especially necessary. After
D Wear is uneven across the tread of any front tire.
rotation, be sure to check wheel nut torque, and set tire
pressures. D Front tire treads have a scuffed appearance with
“feather” edges on one side of the tread ribs or blocks.
Tire Rotation
Tread Wear Indicators
Tire rotation is recommended to equalize wear for longer
tire life.
480RS006
The original equipment tires have built-in tread wear

480RS002
indicators(1) to show when tires need replacement.
Legend These indicators may appear as wide bands. When the
(1) Spare Tire indicators appear in two or more grooves at three
locations, tire replacement is recommended.
Inflation of Tires 6. High tire temperatures.

7. Reduced handling.
8. Reduced fuel economy.
Unequal pressure on same axle can cause:
1. Uneven braking.
2. Steering lead.
3. Reduced handling.
4. Swerve on acceleration.
Radial Tire Waddle
710RS003
Tire pressure, in cold condition (after vehicle has set for

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

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

Step Action Yes No
1 1. Inflate tires to recommended pressure.
2. Road test vehicle on level uncrowned road.
Was a problem corrected? End Go to Step 2
2 Switch front tires side to side and road test again. If roughness
results,replace
Was a problem corrected?
tires Go to Step 3
3 Did the vehicle lead in same direction? Go to Step 4 Go to Step 5
4 Put tires back in original position and check alignment.
Was a problem corrected? End Go to Step 5
5 Install known good tire on one front side. Install a known
good tire in place
Was a problem corrected?
of other front tire.
If lead corrected,
Replace tire replace tire
Typical examples of abnormal tire ahead wear and major Tread wear one-sided.
causes:
CAUTION: Similar wear patterns can be caused by
worn suspension parts, misalignment of wheels and
tires, and other suspension related problems.
Spotty wear – wear localized on shoulder sections, and in

an extreme cases, the tire becomes polygonal in shape.
480RW003
1. Rotating parts out of balance.

2. Tire or wheel out of round.
3. Hub or knuckle out of round or distorted.
480RW002
1. Tire or wheel out of round or distorted.

2. Hub or knuckle out of round or distorted.
3. Play in hub bearings or ball joint.
4. Rotating parts out of balance.
Localized tread wear. Wear in shoulders at points opposed to each other.
480RW004 480RW006
1. Once spotty wear develops in tread due to hard 1. Tire or wheel out of round or distorted.
braking or abrupt starting, localized wear tends to be 2. Play in bearings or ball joint.
promoted.
Premature wear in shoulders.

Shoulder wear (generally wear develops in outer
shoulder):
480RW007
1. Flexing of tire excessive due to under-inflation.

480RW005
1. Camber or toe-in incorrect.

2. Shoulder wear caused by repeated hard-cornering.
One sided feather edging.
480RW008
1. Wear caused by repeated hard-cornering.

2. Camber or toe-in incorrect.
Wheel
Wheel and Associated Parts
480RW001
Legend
(1) Wheel Lug Nut
(2) Wheel and Tire
Removal
1. Loosen wheel lug nut by approximately 180 g (half a
rotation), then raise the vehicle and remove the nuts.
2. Remove wheel and tire.
NOTE: Never use heat to loosen a tight wheel lug nut.
The application of heat to the hub can shorten the life of
the wheel and may cause damage to wheel bearings.
Installation
1. Install wheel and tire.
2. Install wheel lug nut, and lower the vehicle. Tighten
the wheel lug nuts to the specified torque in numerical
order.
CAUTION: Before installing wheels, remove any
build-up of corrosion on the wheel mounting surface 480RS020
and brake disc mounting surface by scraping and

wire brushing. Installing wheels without good
metal-to-metal contact at mounting surfaces can
cause wheel nuts to loosen, which can later allow a
wheel to come off while the vehicle is moving.
NOTE: Valve caps should be on the valve stems to keep
dust and water out.
Tire
Tire Replacement Steel Aluminum
When replacement is necessary, the original metric the 1– Vertical play: 1– Vertical play:
size should be used. Most metric tire sizes do not have Less than Less than
exact corresponding alphanumeric tire sizes. It is 1.5 mm (0.059 in) 0.7 mm (0.028 in)
recommended that new tires be installed in pairs on the
same axle. If necessary to replace only one tire, it should 2– Horizontal play: 2– Horizontal play:
be paired with tire having the most tread, to equalize Less than Less than
braking traction. 1.5 mm (0.059 in) 0.7 mm (0.028 in)
CAUTION: Do not mix different types of tires such
as radial, bias and bias-belted tires except in
emergencies, because vehicle handling may be
seriously affected and may result in loss of control.
Tire Dismounting
Remove valve cap on valve step and deflate the tire. Then
use a tire changing machine to mount or dismount tires.
Follow the equipment manufacturer’s instruction. Do not
use hand tools or tire lever alone to change tires as they
may damage the tire beads or wheel rim.
Tire Mounting
Rim bead seats should be cleaned with a wire brush or
coarse steel wool to remove lubricants, and light rust.
Before mounting a tire, the bead area should be well
lubricated with an approved tire lubricant.
After mounting, inflate the tire to 196kPa (28 psi) so that
beads are completely seated. Inflate the air to specified
pressure and install valve cap to the stem.
480RS012
WARNING: NEVER STAND OVER TIRE WHEN
INFLATING. BEAD MAY BREAK WHEN BEAD SNAPS
OVER RIM’S SAFETY HUMP AND CAUSE SERIOUS General Balance Procedure
PERSONAL INJURY. Deposits of mud, etc. must be cleaned from the inside of
NEVER EXCEED 240 KPA (35 PSI) PRESSURE WHEN the rim.
The tire should be inspected for the following: match
INFLATING. IF 240 KPA (35 PSI) PRESSURE WILL
mount paint marks, bent rims, bulges, irregular tire wear,
NOT SEAT BEADS, DEFLATE, RE-LUBRICATE AND
proper wheel size and inflation pressure. Then balance
RE-INFLATE. OVER INFLATION MAY CAUSE THE according to the equipment manufacturer’s
BEAD TO BREAK AND CAUSE SERIOUS PERSONAL recommendations.
INJURY. There are two types of wheel and tire balance.
Static balance is the equal distribution of weight around
Tire Repair the wheel.
There are many different materials on the market used to Assemblies that are statically unbalanced cause a
repair tires. bouncing action called tramp. This condition will
Manufacturers have published detailed instructions on eventually cause uneven tire wear.
how and when to repair tires. These instructions can be
obtained from the tire manufacturer if they are not
included with the repair kit.
Wheel Inspection
Damaged wheels and wheels with excessive run-out
must be replaced.
Wheel run out at rim (Base on hub Bore):
Balancing Wheel and Tire

On-vehicle Balancing
On-Vehicle balancing methods vary with equipment and
tool manufacturers. Be sure to follow each
manufacturer’s instructions during balancing operation.
Off-vehicle Balancing
Most electronic off-vehicle balancers are more accurate
than the on-vehicle spin balancers. They are easy to use
and give a dynamic balance. Although they do not correct
for drum or disc unbalance (as on- vehicle spin balancing
does), they are very accurate.
480RS013
Legend
(1) Heavy Spot Wheel Shimmy
(2) Add Balance Weights Here
Dynamic balance is the equal distribution of weight on

each side of the wheel center-line so that when the tire
spins there is no tendency for the assembly to move from
side to side. Assemblies that are dynamically unbalanced
may cause shimmy.
480RS015
480RS014
Legend
(1) Heavy Spot Wheel Hop
(2) Add Balance Weights Here
WARNING: STONES SHOULD BE REMOVED FROM

THE TREAD TO AVOID OPERATOR INJURY DURING
SPIN BALANCING AND TO OBTAIN A GOOD
BALANCE.

Wheels Size 16 x 7JJ
Offset 38.0 mm (1.50 in)
P.C.D., wheel studs 139.7 mm (5.50 in)
Standard tire Size P245/70R16
Pressure(Front) 210 kPa (30 psi)
Pressure(Rear) 240 kPa (35 psi)
E03RW002
DIFFERENTIAL (FRONT) 4A1–1
TROOPER
DRIVELINE/AXLE
CONTENTS
Differential (Front) . . . . . . . . . . . . . . . . . . . . . . . 4A1
Differential (Rear) . . . . . . . . . . . . . . . . . . . . . . . 4A2
DIFFERENTIAL (FRONT)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 4A1–1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A1–7
Front Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . 4A1–2 Differential Assembly . . . . . . . . . . . . . . . . . . . . 4A1–9
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A1–2 Disassembled View . . . . . . . . . . . . . . . . . . . . 4A1–9
Pinion Shaft Oil Seal . . . . . . . . . . . . . . . . . . . . . 4A1–3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4A1–9
Pinion Shaft Oil Seal and Associated Parts 4A1–3 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4A1–12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A1–3 Differential Cage Assembly . . . . . . . . . . . . . . . 4A1–21
Inspection and Repair . . . . . . . . . . . . . . . . . . 4A1–4 Disassembled View . . . . . . . . . . . . . . . . . . . . 4A1–21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A1–4 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4A1–21
Front Drive Axle Assembly . . . . . . . . . . . . . . . 4A1–5 Inspection and Repair . . . . . . . . . . . . . . . . . . 4A1–22
Front Drive Axle Assembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4A1–23
Associated Parts . . . . . . . . . . . . . . . . . . . . . . 4A1–5 Main Data and Specifications . . . . . . . . . . . 4A1–25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A1–5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 4A1–27
Service Precaution
RESTRAINT SYSTEM(SRS). REFER TO THE SRS
ARE REFORMING SERVICE ON OR NEAR THE SRS
sealant. UNLESS OTHERWISE SPECIFIED , do not
fastener joint interfaces. Generally,such coatings
sequence and specification. Following these
systems.
4A1–2 DIFFERENTIAL (FRONT)
Front Drive Axle

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

Pinion Shaft Oil Seal and Associated Parts
415RW015
Legend (3) Oil Seal

(1) Flange Nut (4) Outer Bearing
(2) Flange (5) Collapsible Spacer
Removal
1. Raise the vehicle and support it at the frame.
The hoist must remain under the front axle housing.
2. Drain the front axle oil by loosening the drain plug(1).
412RS001
3. Remove the front propeller shaft. Refer to Front Inspection and Repair
Propeller Shaft in this section.
4. Remove flange nut by using pinion flange holder damage, corrosion or any other abnormal conditions are
J–37221. found through inspection.
1. Seal surface of the pinion.
2. Cage bore for burns.
Installation
1. Install collapsible spacer. Discard the used
collapsible spacer and install a new one.
2. Install outer bearing.
NOTE: Do not drive in, but just temporarily set in the outer
bearing by hand, which should be indirectly pressed in
finally by tightening the flange nut.
3. Install oil seal, use oil seal installer J–24250 to install a
new oil seal that has been soaked in axle lubricant.
425RW039
5. Remove flange.
6. Remove oil seal.
7. Remove outer bearing by using remover J–39602.
415RS002
4. Install flange.
5. Install flange nut, refer to Differential Assembly
Overhaul for flange nut reassembly in this section.
NOTE: Discard the used nut and install a new one.
415RW016
8. Remove collapsible spacer.

Front Drive Axle Assembly

Front Drive Axle Assembly and Associated Parts
412RW001
Legend (6) Front Axle Case Assembly and Front Drive

(1) Mounting Bolt and Nut Shaft Assembly (LH side)
(2) Washer and Spacer (7) Hub Assembly (Disc, Back Plate and Knuckle)
(3) Breather Hose (8) Front Drive Shaft Assembly (RH side)
(4) Shift Switch Connector (9) Propeller Shaft (with TOD)
(5) Protector (10) Propeller Shaft
(11) Bolt
Removal
1. Jack up the vehicle and support it using jack stands.
2. Remove the tire and wheel.
3. Remove the drain bolt to drain differential oil. 14. Disconnect shift switch connector.
NOTE:
a. During the work, be sure that the diff case is
supported by the jack.
412RS031
15. Remove VSV assembly (1).

NOTE: Be sure not to remove hose and connector from
412RS003
VSV asm.
b. Remove the brake caliper fixing bolt and hang the
caliper. Refer to Disc Brakes in Brake section.
c. Remove the antilock brake system speed sensor.
Refer to Front Wheel Speed Sensor in Brake
section.
4. Remove the hub assembly (Disc, back plate and
knuckle), refer to Front Hub and Disc in this section.
5. Disconnect the knuckle and the suspension arm.
Refer to Suspension section.
6. Remove steering link and arm assembly, refer to
7. Remove suspension crossmember.
8. Remove propeller shaft, refer to Front Propeller Shaft
in this section.
9. Remove protector.
10. Remove breather hose.
11. Remove the hose clip.
12. Disconnect breather hose from front drive axle tube 412RW002
and disconnect housing.

13. Disconnect vacuum hose from actuator.
16. Remove mounting bolt and nut. 19. Lower the vehicle and disconnect the RH front drive
shaft assembly, then remove the front axle case
assembly and front drive shaft assembly (LH).
412RS004
17. Remove washer and spacer.

18. Remove the mounting bracket fixing bolt. 412RS006
20. Remove front drive shaft assembly (RH).
Installation
1. Install front drive shaft assembly (RH) and lay the
assembly on the lower arm.
2. Install front axle case assembly and front drive shaft
assembly (LH) and place the axle case on the jack,
connect to the front drive shaft assembly (RH) before
installing to the vehicle.
3. Install bolt and tighten the mounting bracket fixing bolt
Torque: 116 N·m (85lb ft)
4. Install washer and spacer.
412RS005
5. Tighten the mounting bolt and nut to the specified
torque.
412RW005
Legend
(1) Frame
(2) Spacer
(3) Washer
(4) Bolt
(5) Nut
6. Install VSV assembly and tighten nuts to specified

torque.
Torque: 8 N·m (69lb in)
7. Install the shift switch connector.
NOTE: Be careful not to permit the entry of dust into the
connector.
8. Install the actuator side of vacuum hose.
NOTE: Be careful not to permit the entry of dust into the
hose.
9. Connect breather hose and install the hose clip.
10. Install protector and tighten bolts to specified torque.
11. Install propeller shaft, refer to Front Propeller Shaft in
this section.
12. Install suspension crossmember.
13. Steering link and arm assembly, refer to Steering
Linkage in Steering section.
14. Install hub assembly (Disc, back plate and knuckle),
refer to Front Hub and Disc in this section.
Differential Assembly
Disassembled View
415RW001
Legend (12) Bolt

(1) Differential Assembly (13) Inner Bearing Outer Race
(2) Flange Nut (14) Collapsible Spacer
(3) Flange (15) Pinion Gear
(4) Dust Cover (16) Inner Bearing
(5) Oil Seal (17) Adjust Shim
(6) Outer Bearing (18) Diff Cage Assembly
(7) Outer Bearing Outer Race (19) Side Bearing Outer Race
(8) Damper (20) Side Bearing
(9) Bracket (21) Adjust Shim
(10) Differential Carrier (22) Bolt
(11) Bearing Cap (23) Axle Case
Disassembly 2. Remove differential assembly.
1. Remove differential carrier fixing bolt.

3. Using holding fixture J–37264 and holding fixture 8. Remove side bearing, using remover J–22888 and
base J–3289–20, fix the differential assembly to the adapter J–8107–2.
bench.
415RS005
425RS008 9. Remove adjust shim, note the thickness and position

4. Remove bearing cap bolt. of the shims removed.
5. Apply a setting mark to the side bearing cap and the 10. Remove the flange nut using holding wrench J–37221
differential carrier then remove bearing cap. after raising up its staked parts completely.
425RS009 425RW040
6. Remove differential cage assembly. 11. Remove flange.

7. Remove side bearing outer race, after removal, keep 12. Remove dust cover.
the right and left hand side bearing assemblies
separate to maintain inner and outer race
combinations.
13. Remove the drive pinion assembly using a soft metal 20. Remove the inner bearing outer race (1) and the outer
rod and a hammer. bearing outer race (2) by using a brass bar and a
hammer.
425RW041
14. Remove collapsible spacer. 425RS014
15. Remove the inner bearing using a separator

J–22912–01 and a press.
425RS015
415RS006
16. Remove adjust shim.

17. Remove inner bearing outer race.
19. Remove outer bearing.
21. Remove damper and bracket. 2. Using installer J–24252 and grip J–8092, install Inner
bearing outer race.
425RW042
415RS008
Reassembly 3. Install adjust shim and adjust drive pinion mounting

distance
1. Using installer J–24256 and grip J–8092, install outer 1. Apply gear oil to the inner and outer drive pinion
bearing outer race. bearing.
Clean the pinion setting gauge set.
Then install the gauge set together with the inner
and outer bearings.
2. Tighten the nut to the specified torque.
Torque: 2.3 N·m (20 lb in)
415RS007
415RS009
Legend
(1) Pilot : J–21777–42
(2) Nut and Bolt : J–23597–9
(3) Gauge Plate : J–23597–7
3. Clean the side bearing bores. Install the dial Legend
indicator with the discs and arbor. Install and (1) Dial Indicator
tighten the bearing caps to the specified torque. (2) Ganging Arbor
Torque: 98 N·m (72 lb ft) (3) Plunger
(4) Gauge Plate
5. Position the plunger on the gauge plate. Move the

gauging arbor slowly back and forth and locate
the position at which the dial indicator shows the
greatest defection. At this point, once again set
the dial indicator to “0”.
Repeat the procedure to verify the “0” setting.
415RS010
Legend
(1) Dial Indicator: J–8001
(2) Disc (2 pcs.): J–23597–8
(3) Arbor: J–23597–1
(4) Gauge Plate: J–23597–42
4. Set the dial indicator to “0”. Place it on the 425RS021
mounting post of the gauging arbor with the 6. After the ZERO setting is obtained, rotate the
contact button touching the indicator pad. Force gauging arbor until the dial indicator rod does not
the dial indicator downward until the needle has touch the gauging plate.
made a half turn clockwise. Tighten down the dial
indicator in this position. Record the number the dial indicator needle
points to.
425RS020
425RS022
Legend
(1) Example=Dial indicator reading of 0.085
7. Record the pinion depth code on the head of the

drive pinion.
The number indicates a necessary change in the
pinion mounting distance. A plus number indi-
cates the need for a greater mounting distance
(which can be achieved by decreasing the shim
thickness). A minus number indicates the need
for a smaller mounting distance (which can be
achieved by increasing the shim thickness). If ex-
amination reveals pinion depth code “0”, the pin-
ion is “nominal”.
425RS023
8. Select the shim using the chart;
Pinion marking +10 +8 +6 +4 +2 0 –2 –4 –6 –8 –10
Dial indicator
reading mm mm mm mm mm mm mm mm mm mm mm
(Inches) (Inches) (Inches) (Inches) (Inches) (Inches) (Inches) (Inches) (Inches) (Inches) (Inches) (Inches)
2.18
0.081
(0.0858)
2.18 2.20
0.082
(0.0858) (0.0866)
2.18 2.20 2.23

0.083
(0.0858) (0.0866) (0.0882)
2.18 2.20 2.24 2.26

0.084
(0.0858) (0.0866) (0.0882) (0.0890)
2.18 2.20 2.24 2.26 2.28

0.085
(0.0858) (0.0866) (0.0882) (0.0890) (0.0898)
2.18 2.20 2.24 2.26 2.28 2.32

0.086
(0.0858) (0.0866) (0.0882) (0.0890) (0.0898) (0.0914)
2.18 2.20 2.24 2.26 2.28 2.32 2.34

0.087
(0.0858) (0.0866) (0.0882) (0.0890) (0.0898) (0.0914) (0.0921)
2.18 2.20 2.24 2.26 2.28 2.32 2.34 2.36

0.088
(0.0858) (0.0866) (0.0882) (0.0890) (0.0898) (0.0914) (0.0921) (0.0929)
2.18 2.20 2.24 2.26 2.28 2.32 2.34 2.36 2.38

0.089
(0.0858) (0.0866) (0.0882) (0.0890) (0.0898) (0.0914) (0.0921) (0.0929) (0.0937)
2.18 2.20 2.24 2.26 2.28 2.32 2.34 2.36 2.38 2.42
0.090
(0.0858) (0.0866) (0.0882) (0.0890) (0.0898) (0.0914) (0.0921) (0.0929) (0.0937) (0.0953)
2.18 2.20 2.24 2.26 2.28 2.32 2.34 2.36 2.38 2.42 2.44
0.091
(0.0858) (0.0866) (0.0882) (0.0890) (0.0898) (0.0914) (0.0921) (0.0929) (0.0937) (0.0953) (0.0961)
2.20 2.24 2.26 2.28 2.32 2.34 2.36 2.38 2.42 2.44 2.46
0.092
(0.0866) (0.0882) (0.0890) (0.0898) (0.0914) (0.0921) (0.0929) (0.0937) (0.0953) (0.0961) (0.0969)
2.24 2.26 2.28 2.32 2.34 2.36 2.38 2.42 2.44 2.46 2.48
0.093
(0.0882) (0.0890) (0.0898) (0.0914) (0.0921) (0.0929) (0.0937) (0.0953) (0.0961) (0.0969) (0.0977)
2.26 2.28 2.32 2.34 2.36 2.38 2.42 2.44 2.46 2.48 2.52
0.094
(0.0890) (0.0898) (0.0914) (0.0921) (0.0929) (0.0937) (0.0953) (0.0961) (0.0969) (0.0977) (0.0992)
2.28 2.32 2.34 2.36 2.38 2.42 2.44 2.46 2.48 2.52 2.54
0.095
(0.0898) (0.0914) (0.0921) (0.0929) (0.0937) (0.0953) (0.0961) (0.0969) (0.0977) (0.0992) (0.1000)
2.32 2.34 2.36 2.38 2.42 2.44 2.46 2.48 2.52 2.54 2.56
0.096
(0.0914) (0.0921) (0.0929) (0.0937) (0.0953) (0.0961) (0.0969) (0.0977) (0.0992) (0.1000) (0.1008)
2.34 2.36 2.38 2.42 2.44 2.46 2.48 2.52 2.54 2.56
0.097
(0.0921) (0.0929) (0.0937) (0.0953) (0.0961) (0.0969) (0.0977) (0.0992) (0.1000) (0.1008)
2.36 2.38 2.42 2.44 2.46 2.48 2.52 2.54 2.56

0.098
(0.0929) (0.0937) (0.0953) (0.0961) (0.0969) (0.0977) (0.0992) (0.1000) (0.1008)
2.38 2.42 2.44 2.46 2.48 2.52 2.54 2.56

0.099
(0.0937) (0.0953) (0.0961) (0.0969) (0.0977) (0.0992) (0.1000) (0.1008)
2.42 2.44 2.46 2.48 2.52 2.54 2.56

0
(0.0953) (0.0961) (0.0969) (0.0977) (0.0992) (0.1000) (0.1008)
2.44 2.46 2.48 2.52 2.54 2.56

0.001
(0.0961) (0.0969) (0.0977) (0.0992) (0.1000) (0.1008)
2.46 2.48 2.52 2.54 2.56

0.002
(0.0969) (0.0977) (0.0992) (0.1000) (0.1008)
2.48 2.52 2.54 2.56

0.003
(0.0977) (0.0992) (0.1000) (0.1008)
2.52 2.54 2.56

0.004
(0.0992) (0.1000) (0.1008)
2.54 2.56
0.005
(0.1000) (0.1008)
2.56
0.006
(0.1008)
NOTE: When ordering shims, find the part number in the 4. Place the shim on the drive pinion, with the chamfered
parts catalog by using the thickness of shims listed in the side turned towards the pinion head then install the
above table. inner bearing onto the pinion using an installer
J–6133–01 and a press.
NOTE: Do not apply pressure to the roller cage and apply 2. Tighten the nut to the specified torque using the
pressure only to the inner race. pinion flange holder J–37221.
Torque: 177–275N·m (130–203 lb ft)
NOTE: Discard used flange nut and install new one and
do not over tighten the flange nut.
425RS024
5. Discard the used collapsible spacer and install a new

one.
6. Install pinion gear.
7. Install outer bearing. 425RW040
3. Adjust pinion bearing preload.

8. Use oil seal installer J–24250 to install a new oil seal
that has been soaked in rear axle lubricant. a. Measure the bearing preload by using a torque
meter. Note the scale reading required to
NOTE: Take care to use a front differential oil seal, NOT rotate the flange.
the rear differential oil seal.
b. Continue tightening flange nut until the
specified starting torque is obtained.
Starting torque:
New bearing 0.7–1.1 N·m(5.64–9.98 lb in)
Used bearing 0.4–0.5N·m(2.86–4.94Ib in)
415RS011
9. Install dust cover.

10. Install flange.
11. Install flange nut.
1. Apply lubricant to the pinion threads.
425RS027
4. Using punch J–39209, stake the flange nut at two

points.
NOTE: When staking, be sure to turn the nut to insure 2. Insert the differential cage assembly with bearing
that there is no change in bearing preload. Make sure of outer races into the side bearing bores of the
preload again as instructed in 3). carrier.
415RS012 425RS030
Legend 3. Using two sets of feeler gauges, insert a feeler

(1) 1.3mm or less stock of sufficient thickness between each
bearing outer race and the carrier to remove all
12. Install adjust shim. end play. Make certain the feeler stock is pushed
to the bottom of the bearing bores.
1. Attach the side bearing to the differential
assembly without shims. Support the opposite Mount the dial indicator J–8001 on the carrier so
side using a pilot to prevent bearing damage. that the indicator stem is at right angles to a tooth
on the ring gear.
425RS029
425RS031
Legend
(1) Drive handle:J–8092
(2) Installer:J–24244
(3) Pilot:J–8107–2
4. Adjust feeler gauge thickness from side to side 13. Install the side bearings together with the selected
until ring gear backlash is in the specified range. shims.
Backlash: 0.13–0.18 mm(0.005 –0.007 in)
425RS029
425RS032
Legend
With zero end play and correct backlash estab- (1) Drive Handle:J–8092
lished, remove the feeler gauge packs, determine (2) Installer: J–24244
the thickness of the shims required and add 0.05 (3) Pilot: J–8107–2
mm (0.002 in) to each shim pack to provide side
bearing preload. Always use new shims. 14. Install side bearing outer race.
5. Use bearing remover J–22888 and pilot 15. Install differential cage assembly.
J–8107–2 to remove side bearing.
16. Install bearing cap then align the setting marks(1)
applied at disassembly.
415RS013
425RS035
17. Tighten the cap bolt to the specified torque. Gear Tooth Contact Pattern Check and Adjustment
Torque: 98 N·m (72 lb ft) 1. Apply a thin coat of prussian blue or equivalent
to the faces of the 7–8 teeth of the ring gear.
Check the impression of contact on the ring
gear teeth and make necessary adjustment as
described in illustration if the contact is
abnormal.
425RS036
1. Measure the amount of run–out of the ring gear at

its rear face.
Standard: 0.02 mm ( 0.001 in)
Limit: 0.05 mm ( 0.002 in) 425RS038
Legend
(1) Heel
(2) Toe
(3) Concave Side(Coast)
(4) Convex Side(Drive)
425RS037
425RS039
18. Install differential assembly. 3. Fill the axle case with hypoid gear lubricant, to just
1. Clean the faces of the front axle case and below the filler hole.
differential carrier. Lubricant capacity: 1.4 liter(1.5 US qt)
Apply Three Bond TB1215 or equivalent to the
19. Install damper.
sealing side of the axle case and the carrier.
1. Clean the faces and bolt thread hole of differential
2. Attach the differential case and the carrier
carrier.
assembly to the front axle case and tighten the
nuts and bolts. 2. Install the bracket with new bolts.
Torque: 25 N·m (19 lb ft) 3. Install the damper to the bracket with new bolts.
415RS014
425RW042
Differential Cage Assembly

Disassembled View
415RS015
Legend (5) Ring Gear

(1) Pinion Gear (6) Bolt
(2) Thrust Washer (7) Differential Cage
(3) Side Gear (8) Lock Pin
(4) Cross Pin
Disassembly
1. Remove bolt.
2. Remove ring gear.
3. Remove lock pin, break staking on the lock pin, using
a 5 mm (0.20 in) diameter drill.
425RS042
4. Remove the cross pin, using a soft metal rod and a 5. Tighten the fixing bolts in a diagonal sequence as
hammer. illustrated.
425RS043 415RS016
5. Remove pinion gear.

6. Remove side gear.
Clearance between the differential pinion
and the cross pin measurement:
7. Remove thrust washer.
Standard: 0.06 – 0.12 mm (0.002–0.005 in)
Inspection and Repair Limit: 0.2 mm (0.008 in)
1. Ring gear, pinion gear
2. Bearing
3. Side gear, pinion gear, cross pin
4. Differential cage, carrier
5. Thrust washer
6. Oil seal
Ring gear replacement:
1. The ring gear should always be replaced with the
drive pinion as a set.
2. Clean the ring gear threaded holes to remove the
locking agent.
3. When installing the ring gear, apply LOCTITE 271 or
equivalent to all the threaded area and half of the
unthreaded area of the bolt. 425RS045
4. Discard used bolts and install new ones.

Clearance between the side gear and the Reassembly
differential box:
1. Install thrust washer.
Standard: 0.03–0.10 mm (0.001–0.004 in) 2. Install side gear.
Limit: 0.15 mm(0.006 in) 3. Install the pinion gear by engaging it with the side
gears while turning both pinion gears simultaneously
in the same direction.
425RS046
Legend
425RS048
(1) Side Gear 4. Install cross pin.
(2) Differential Box
1. Be sure to install the cross pin so that it is in
alignment with the lock pin hole in the differential
Play in splines between the side gear and cage.
the axle shaft:
Standard: 0.08–0.36 mm(0.003 –0.014 in)
Limit:0.5m (0.02 in)
425RS049
2. Adjust the backlash between the side gear and

the pinion gear.
Backlash:0.03 – 0.08 mm (0.001– 0.003 in)
425RS047
Thickness of thrust washers available: 7. Tighten the bolts in diagonal sequence as illustrated.
1.00 mm, 1.05 mm, 1.10 mm (0.039 in, 0.041 in, Torque: 108 N·m (80 lb ft)
0.043 in)
NOTE: Discard used bolts and install new ones.
425RS050
5. Install lock pin. After lock pin installation, stake the 415RS016
cage to secure the lock pin.
425RS051
Legend
(1) Staked Portion
(2) Lock Pin

locking agent. When installing the ring gear, apply
LOCTITE 271 or equivalent to all the threaded area
and half of the unthreaded area of the bolt.

Axle tube Type It consists of the duct, a cast iron housing and the axle
tube.
Gear type Hypoid
Gear ratio (to 1) 4.300
Differential type Two pinion
Oil capacity liter (US qt) 1.4 (1.5) (Differential)
0.12 (0.13) (Actuator Housing: Shift on the fly)
Type of lubricant 75W–90 GL–5 (Multi grade type)
Refer to General Information
Axle shaft type Constant velocity joint (Birfield joint type and double
offset joint)
Hub locking Type Rigid
E04RW002
E04RW003
Special Tools
TOOL NO. TOOL NO.
TOOL NAME TOOL NAME
J–37221 J–22912–01
Holder; Pinion flange Separator
J–24250 J–24256
Installer; Oil seal Installer; Outer bearing
outer race
J–37264
Differential holding
fixture J–8092
(Use with J–3289–20 Driver handle
base)
J–3289–20 J–24252
Holding fixture base Installer; Inner bearing
outer race
J–22888 J–21777–42
Puller; Side bearing Pilot
J–8107–2
Adapter; Side bearing J–23597–9
plug Nut and bolt
TOOL NO. TOOL NO.

TOOL NAME TOOL NAME
J–23597–7 J–24244
Gauge plate Installer; Side bearing
J–8001 J–39602
Dial indicator Remover; Outer bearing
J–23597–8
Disc
J–23597–1
Arbor
J–6133–01
Installer; Pinion bearing
J–39209
Punch; End nut lock
DIFFERENTIAL (REAR) 4A2–1
TROOPER
DRIVELINE/AXLE
DIFFERENTIAL (REAR)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 4A2–1 Differential Assembly . . . . . . . . . . . . . . . . . . . . 4A2–12
General Description . . . . . . . . . . . . . . . . . . . . . 4A2–3 Differential Assembly and Associated Parts 4A2–12
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2–4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2–12
Axle Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2–5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2–13
Axle Housing and Associated Parts . . . . . . 4A2–5 Disassembled View . . . . . . . . . . . . . . . . . . . . 4A2–14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2–5 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2–15
Oil Seal Replacement . . . . . . . . . . . . . . . . . . 4A2–6 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2–17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2–6 Differential Cage Assembly . . . . . . . . . . . . . . . 4A2–24
Axle Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2–7 Disassembled View . . . . . . . . . . . . . . . . . . . . 4A2–24
Axle Shaft and Associated Parts . . . . . . . . . 4A2–7 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2–25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2–7 Inspection and Repair . . . . . . . . . . . . . . . . . . 4A2–25
Inspection and Repair . . . . . . . . . . . . . . . . . . 4A2–8 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2–26
Oil Seal Replacement . . . . . . . . . . . . . . . . . . 4A2–9 Limited Slip Differential . . . . . . . . . . . . . . . . . . . 4A2–28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2–9 Disassembled View . . . . . . . . . . . . . . . . . . . . 4A2–28
Pinion Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2–10 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2–29
Pinion Oil Seal and Associated Parts . . . . . 4A2–10 Inspection and Repair . . . . . . . . . . . . . . . . . . 4A2–29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2–10 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2–31
Inspection and Repair . . . . . . . . . . . . . . . . . . 4A2–11 Main Data and Specifications . . . . . . . . . . . . . 4A2–35
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2–11 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2–36

RESTRAINT SYSTEM(SRS). REFER TO THE SRS ISUZU will call out those fasteners that require a
PERFORMING SERVICE ON OR NEAR THE SRS sealant. UNLESS OTHERWISE SPECIFIED , do not
ARE REFORMING SERVICE ON OR NEAR THE SRS corrosion inhibitors) on threaded fasteners or
COMPONENTS OR THE SRS WIRING, REFER TO fastener joint interfaces. Generally,such coatings
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. sequence and specification. Following these
systems.
The f244 differential has two N types A-type and B-
type.
A-type: the sticker with bar code is attached.
B-type: the sticker with no bar code on the lower part
of carrier is attached.
4A2–2 DIFFERENTIAL (REAR)
In case of Work Shop Manual;

A-type: Refer to ’98 UBS Work Shop Manual.
B-type: Described in ’00UBS Work Shop Manual.
425RY00018
General Description
The rear axle assembly is of the semi–floating type in driving force at a 90 degree angle from the propeller shaft
which the vehicle weight is carried on the axle housing . to the drive shafts.
The center line of the pinion gear is below the center line The axle shafts are supported at the wheel end of the
of the ring gear (hypoid drive). shaft by a roller bearing.
All parts necessary to transmit power from the propeller The pinion gear is supported by two tapered roller
shaft to the rear wheels are enclosed in a banjo type axle bearings. The pinion depth is set by a shim pack located
housing. between the gear end of the pinion and the roller bearing
The 9.61 inch ring gear rear axle uses a conventional ring that is pressed onto the pinion. The pinion bearing
and pinion gear set to transmit the driving force of the preload is set by crushing a collapsible spacer between
engine to the rear wheels. This gear set transfers this the bearings in the axle housing.
420RY00003
The ring gear is bolted onto the differential cage with 12 are pressed onto the differential cage. Two bearing caps
bolts. are used to hold the differential into the rear axle housing.
The differential cage is supported in the axle housing by The differential is used to allow the wheels to turn at
two tapered roller bearings. The differential and ring gear different rates of speed while the rear axle continues to
are located in relationship to the pinion by using selective transmit the driving force. This prevents tire scuffing
shims and spacers between the bearing and the axle when going around corners and prevents premature wear
housing. To move the ring gear, shims are deleted from on internal axle parts.
one side and an equal amount are added to the other side. The rear axle is sealed with a pinion seal, a seal at each
These shims are also used to preload the bearings which axle shaft end, and by a liquid gasket between the
differential carrier and the axle housing.
Diagnosis Gear Noise

Many noises that seem to come from the rear axle Gear noise (whine) is audible from 32 to 89 km/h (20 to 55
actually originate from other sources such as tires, road mph) under four driving conditions.
surface, wheel bearings, engine, transmission, muffler, or 1. Driving under acceleration or heavy pull.
body drumming. Investigate to find the source of the 2. Driving under load or under constant speed.
noise before disassembling the rear axle. Rear axles, like
any other mechanical device, are not absolutely quiet but 3. When using enough throttle to keep the vehicle from
should be considered quiet unless some abnormal noise driving the engine while the vehicle slows down
is present. gradually (engine still pulls slightly).
To make a systematic check for axle noise, observe the 4. When coasting with the vehicle in gear and the throttle
following: closed. The gear noise is usually more noticeable
1. Select a level asphalt road to reduce tire noise and between 48 and 64 km/h (30 and 40 mph) and 80 and
body drumming. 89 km/h (50 and 55 mph).
2. Check rear axle lubricant level to assure correct level, Bearing Noise
and then drive the vehicle far enough to thoroughly
warm up the rear axle lubricant. Bad bearings generally produce a rough growl or grating
sound, rather than the whine typical of gear noise.
3. Note the speed at which noise occurs. Stop the
Bearing noise frequently “wow–wows” at bearing rpm,
vehicle and put the transmission in neutral. Run the
indicating a bad pinion or rear axle side bearing. This
engine speed slowly up and down to determine if the
noise is caused by exhaust, muffler noise, or other noise can be confused with rear wheel bearing noise.
engine conditions.
Rear Wheel Bearing Noise
4. Tire noise changes with different road surfaces; axle
noises do not. Temporarily inflate all tires to 344 kPa Rear wheel bearing noise continues to be heard while
(50 psi) (for test purposes only). This will change coasting at low speed with transmission in neutral. Noise
noise caused by tires but will not affect noise caused may diminish by gentle braking. Jack up the rear wheels,
by the rear axle. spin them by hand and listen for noise at the hubs.
Rear axle noise usually stops when coasting at Replace any faulty wheel bearings.
speeds under 48 km/h (30 mph); however, tire noise
continues with a lower tone. Rear axle noise usually Knock At Low Speeds
changes when comparing pull and coast, but tire Low speed knock can be caused by worn universal joints
noise stays about the same. or a side gear hub counter bore in the cage that is worn
Distinguish between tire noise and rear axle noise by oversize. Inspect and replace universal joints or cage and
noting if the noise changes with various speeds or side gears as required.
sudden acceleration and deceleration. Exhaust and
axle noise vary under these conditions, while tire Backlash Clunk
noise remains constant and is more pronounced at Excessive clunk on acceleration and deceleration can be
speeds of 32 to 48 km/h (20 to 30 mph). Further check caused by a worn rear axle pinion shaft, a worn cage,
for tire noise by driving the vehicle over smooth excessive clearance between the axle and the side gear
pavements or dirt roads (not gravel) with the tires at splines, excessive clearance between the side gear hub
normal pressure. If the noise is caused by tires, it will and the counterbore in the cage, worn pinion and side
change noticeably with changes in road surface. gear teeth, worn thrust washers, or excessive drive pinion
5. Loose or rough front wheel bearings will cause noise and ring gear backlash. Remove worn parts and replace
which may be confused with rear axle noise; however, as required. Select close–fitting parts when possible.
front wheel bearing noise does not change when Adjust pinion and ring gear backlash.
comparing drive and coast. Light application of the
brake while holding vehicle speed steady will often
cause wheel bearing noise to diminish. Front wheel
bearings may be checked for noise by jacking up the
wheels and spinning them or by shaking the wheels to
determine if bearings are loose.
6. Rear suspension rubber bushings and spring
insulators dampen out rear axle noise when correctly
installed. Check to see that there is no link or rod
loosened or metal–to–metal contact.
7. Make sure that there is no metal–to–metal contact
between the floor and the frame.
After the noise has been determined to be in the axle, the
type of axle noise should be determined, in order to make
any necessary repairs.
Axle Housing
Axle Housing and Associated Parts
420RY00001
Legend (9) Nut

(1) Coil Spring and Insulator (10) Differential Assembly
(2) Axle Housing Assembly (11) Axle Shaft Assembly
(3) ABS Speed Sensor and Harness (12) Brake Disc
(4) Nut (13) Brake Pipe
(5) Parking Brake Cable (14) Brake Caliper
(6) Bolt and Nut (15) Nut
(7) Antilock Brake System (ABS) Connector and (16) Breather Hose
Bracket (17) Flare Nut
(8) Bolt and Nut
Removal 4. Remove propeller shaft. Refer to Rear Propeller

Shaft in this section.
1. Raise the vehicle and support it with suitable safety 5. Drain the rear axle oil into a proper container.
stands.
6. Remove parking brake cable, release the connection
The hoist must remain under the rear axle housing.
between the cable fixing clip equalizer. Refer to
2. Remove brake fluid. Refer to Hydraulic Brakes in Parking Brakes in Brake section.
Brake section. 7. Move the clip aside and pull out the breather hose.
3. Remove rear wheels and tires. Refer to Wheel in
Suspension section.
8. Disconnect the ABS connectors (1) and remove the 19. Remove antilock brake system speed sensor fixing
brackets (2) attached to the frame and center link. bolt and the clip and bracket on the axle housing.
20. Remove the brake pipe clip and fixing bolt on the axle
housing and take out the brake pipe.
21. Remove the bearing holder fixing nut and take out the
axle shaft assembly, be sure not to damage the oil
seal by the spline of the shaft, Refer to Axle Shaft in
this section.
22. Remove differential assembly, refer to Differential
Assembly in this section.
Oil Seal Replacement

Remove the oil seal, carefully not to damage the housing,
and mount new oil seal using oil seal installer J–39210.
350RS001
9. Loosen the brake tube flare nut, remove the clip and
take out the brake tube.
10. Remove the shock absorber fixing nut from the axle
housing.
11. Remove the stabilizer linkage mounting nut from the
axle housing.
12. Remove the lateral rod fixing nut from the axle
housing.
13. Remove the center link mounting bolt and nut from
the axle housing.
14. Remove the trailing link fixing bolt and nut from the
axle housing. 420RS004
15. Jack down and remove the coil spring and insulator.
16. Axle housing assembly can be separated from the Installation
vehicle on completion of steps 1 – 11.
17. Remove the brake caliper fixing bolt (3), loosen the 1. Install differential assembly, refer to Differential
flare nut (1), release the clip (2) and take out the brake Assembly in this section.
caliper together with the flexible hose. 2. Install axle shaft assembly then tighten the bearing
holder mounting nut to the specified torque. Be sure
not to damage the oil seal by the spline of the shaft.
Torque: 74N·m (54lb ft)
3. Install brake pipe.
4. Connect antilock brake system (ABS) speed sensor
and harness, refer to 4–Wheel Anti–Lock Brake
System (ABS) in Brake section.
5. Install brake disc.
6. Install brake caliper. Refer to Disk Brakes in Brake
section.
7. Install axle housing assembly.
8. Install coil spring and insulator.
9. Install the trailing link fixing bolt and nut to the axle
housing. For the procedures in items 9–13, refer to
Suspension section.
10. Install the center link bolt and nut to the axle housing.
11. Install the lateral rod fixing nut to the axle housing.
306RS001 12. Install the stabilizer linkage mounting nut to the axle
18. Remove brake disc. housing.
13. Install the shock absorber fixing nut to the axle 16. Connect breather hose.
housing. 17. Install parking brake cable, Refer to Parking Brakes in
14. Install brake tube flare nut, Refer to Disk Brakes in Brake section.
Brake section. 18. Bleed brakes. Refer to Hydraulic Brakes in Brake
15. Install ABS connector and bracket. section.
Axle Shaft
Axle Shaft and Associated Parts
420RY00005
Legend (7) Bearing Holder

(1) Brake Caliper (8) Bearing
(2) Brake Disc (9) Retainer
(3) Wheel Pin (10) Snap Ring
(4) Axle Shaft Assembly (11) Bolt
(5) Back Plate (12) Nut
(6) Parking Brake Assembly (13) Antilock Brake System (ABS) Speed Sensor
Removal 3. Remove brake caliper. Use a wire to attach the brake

caliper to the frame. Refer to Disk Brakes in Brake
1. Raise the vehicle. section.
2. Remove tires and wheels. Refer to Wheel in Steering 4. Remove brake disc.
section. 5. Remove ABS sensor.
6. Remove Parking brake assembly. Refer to Parking
Brakes in Brake section.
7. Remove the parking brake cable mounting 15. Remove the wheel pins using a remover J–6627–A.
bolts(Behind the back plate)(1).
420RS007
311RS001
8. Remove the bearing holder mounting nuts. Inspection and Repair

9. Remove axle shaft assembly.
NOTE: Be sure not to damage the oil seal. corrosion or any other abnormal conditions are found
10. Remove snap ring. through inspection.
11. Using a bearing remover J–39211 and press, remove Visual Check:
retainer together with the bearing holder. Check the following parts for wear, damage, noise or any
other abnormal conditions:
1. Axle shaft
2. Bearing
When checking the axle shaft, pay special attention to the
splined portions and replace the shaft if distortion or step
wear is noticeable. Correct slight step wear with a grinder.
420RS006
12. Remove bearing.

13. Remove bearing holder.
420RS008
Axle Shaft Run–out Oil Seal Replacement

Limit: 1.0 mm (0.039 in) Remove the oil seal carefully not to damage the bearing
holder bore .
When installing, use oil seal installer J–39379.
420RS009
Axle Shaft Flange Run–out 420RS011
Limit: 0.08 mm (0.003 in)

Installation
1. Install wheel pin.
3. Install bearing holder.
4. Install bearing.
5. Install retainer by using a bearing installer J–39212,
press fit together with the bearing.
420RS010
420RS012
6. Install snap ring. 10. Install parking brake assembly, refer to Parking
7. Install axle shaft assembly. Brakes in Brake section.
11. Install antilock brake system sensor.
NOTE: Be sure not to damage the oil seal.
12. Install brake disc.
8. Tighten the bearing holder mounting nut to the
specified torque. 13. Install brake caliper, refer to Disk Brakes in Brake
section.
Torque: 74N·m (54 Ib ft)
9. Fix the parking brake cable mounting bolt (Behind the
back plate).
Pinion Oil Seal

Pinion Oil Seal and Associated Parts
425RY00010
Legend (3) Oil Seal

(1) Flange Nut and Washer (4) Outer Bearing
(2) Flange (5) Collapsible Spacer
Removal
1. Remove the rear propeller shaft. Refer to Rear
Propeller Shaft in this section.
2. Drain the rear axle oil.
3. Remove flange nut and washer by using pinion flange Inspection and Repair
holder J–8614–01 after raising up its staked parts
completely. Make necessary correction or parts replacement if wear,
1. Seal surface of the pinion.
2. Cage bore for burns.
Installation
1. Install collapsible spacer, discard the used collapsible
spacer and install a new one.
NOTE: Do not drive in, but just temporarily set in the outer
bearing by hand, which should be indirectly pressed in
finally by tightening the flange nut.
3. By using the seal installer J–37263, install a new oil
seal (1) that has grease on seal lip.
415RS018
4. Remove flange.
5. Remove oil seal.
6. Remove outer bearing by using remover J–39602.
425RS004
4. Install flange.
5. Install flange nut and washer. Refer to Differential
Assembly in this section for flange nut reassembly.
NOTE: Discard the used nut and install a new one.
425RY00003

Differential Assembly
Differential Assembly and Associated Parts
425RY00004
Legend (3) Parking Brake Cable

(1) Bolt and Nut (4) Differential Assembly
(2) Axle Shaft Assembly (5) Nut
Removal 6. Remove the parking brake cable fastening clip and

disconnect the equalizer section. Refer to Parking
1. Jack up and support the frame with stands. Brakes in Brake section.
2. Remove the wheel and tire. Refer to Wheel in 7. Remove the bearing holder fixing nuts.
Steering section. 8. Remove axle shaft assembly, be sure not to damage
3. Drain the differential oil. the oil seal by axle shaft.
4. Remove the propeller shaft. Refer to Rear Propeller 9. Remove differential carrier mounting bolts and nuts.
Shaft in this section. 10. Remove differential assembly.
5. Remove the ABS speed sensor. Refer to 4–Wheel
Anti–lock Brake System (ABS) in Brake section.
Installation 2. Install bolt and nut. Tighten the differential carrier

mounting bolts and nuts to the specified torque.
1. Clean the contact surfaces of the axle and differential
Torque:Nuts 44N·m (33lb ft)
carrier. As shown in the drawing, apply Three Bond
TB1215 or equivalent then install differential Bolts 66N·m (48lb ft)
assembly. 3. Install axle shaft assembly. Be sure not to damage
the oil seal by axle shaft.
4. Install nut, refer to Axle Shaft in this section.
5. Install parking brake cable, refer to Parking Brakes in
Brake section.
NOTE: After completing the assembling work, fill the
prescribed gear oil to the filler hole.
Lubricant capacity: 3.0 liter (3.2 US qt)
6. Tighten the oil filler plug to the specified torque.
Torque: 78N·m (58lb ft)
425RS006
Disassembled View
415RY00002
Legend (10) Inner Bearing Outer Race

(1) Flange Nut and Washer (11) Collapsible Spacer
(2) Flange (12) Inner Bearing
(3) Oil Seal (13) Adjust Shim (Pinion Position)
(4) Oil Seal Slinger (14) Drive Pinion Shaft
(5) Outer Bearing (15) Adjust Shim (Diff Cage Assembly)
(6) Outer Bearing Outer Race (16) Diff Preload/Backlash
(7) Diff Carrier (17) Side Bearing
(8) Bearing Cap (18) Side Bearing Outer Race
(9) Bolt
Disassembly 3. Remove differential cage assembly.

4. Remove side bearing outer race. After removal, keep
1. Using holding fixture J–42832 and holding fixture the right and left hand side bearing assemblies
base J–3289–20, fix the differential assembly to the separate to maintain inner and outer race
bench. combinations.
5. Remove side bearing by using remover J–42379 and
adapter J–8107–3. Select collet halves 44803 in
remover kit J–42379 for side bearing removal and
insert is not required for this operation.
425RW035
2. Apply a setting mark to the side bearing cap and the

differential carrier then remove bearing cap.
415RW003
6. Note the thickness and position of the shims then

remove adjust shim.
7. Remove the flange nut and washer by using pinion
flange holder J–8614–01 after raising up its staked
parts completely.
425RS009
415RS018
8. Removed flange assembly. 16. Remove the inner bearing outer race (1) and the outer
9. Remove the drive pinion assembly using a soft metal bearing outer race (2) by using a brass bar and a
rod and a hammer. hammer.
425RS014
425RY005

11. Remove the inner bearing by using remover
J–42379.Select insert 303174 and collet halves
44803 in remover kit J–42379 for inner bearing
removal.
425RS015
415RW004
12. Remove adjust shim.

14. Remove oil seal slinger.
15. Remove outer bearing.
Reassembly 2. Tighten the nut to the specified torque.
1. Install outer bearing outer race by using installer Torque: 2.3 N·m (20 lb in)
J–44461 and grip J–8092.
425RW030
425RY00011 3. Clean the side bearing bores. Place discs and dial
2. Install inner bearing outer race by using installer indicator on to arbor, and place tool into position in
J–44462 and grip J–8092. side bearing bores. Install and tighten the bearing
caps to the specified torque.
425RY00012
3. Adjust the drive pinion mounting distance as follows: 425RW031
1. Apply gear oil to the inner and outer drive pinion Legend
bearing. Clean the pinion setting gauge set. (1) Dial Indicator: J–8001
Then install the gauge set together with the inner (2) Gauge Plate: J–44451
and outer bearings.
(3) Disc (2 pcs.): J–44452
Install gauge plate J–42826 (3), inner pilot J–42827
(2) ,stud and nut J–21777–43 (4) and outer pilot (4) Arbor: J–23597–1
J–42824 (1) through inner and outer bearings.
4. Set the dial indicator J–8001 to “0”. Place it on the 6. After the ZERO setting is obtained, rotate the
mounting post of the gauging arbor with the gauging arbor until the dial indicator rod does not
contact button touching the indicator pad. Force touch the gauging plate. Record the number the
the dial indicator downward until the needle has dial indicator needle points to.
made a half turn clockwise. Tighten down the dial
indicator in this position.
425RS022
Legend
425RS020
(1) Example=Dial indicator reading od 0.085
Legend
(1) Dial Indicator 7. Record the pinion depth code on the head of the
(2) Ganging Arbor drive pinion. The number indicates a necessary
(3) Plunger change in the pinion mounting distance. A plus
(4) Gauge Plate number indicates the need for a greater mounting
distance (which can be achieved by decreasing
5. Position the plunger on the gauge plate. Move the the shim thickness). A minus number indicates
gauging arbor slowly back and forth and locate the need for a smaller mounting distance (which
the position at which the dial indicator shows the can be achieved by increasing the shim
greatest defection. At this point, once again set thickness). If examination reveals pinion depth
the dial indicator to “0”. Repeat the procedure to code “0”, the pinion is “nominal”.
verify the “0” setting.
425RS023
425RS021
8. Select the shim thickness using the chart;
Pinion
marking
Dial +10 +9 +8 +7 +6 +5 +4 +3 +2 +1 0 –1 –2 –3 –4 –5 –6 –7 –8 –9 –10
indicator
reading
(inches)
0.080 2.12 2.12

(0.0835) (0.0835)
0.081 2.12 2.12 2.14 2.14 2.16

(0.0835) (0.0835) (0.0843) (0.0843) (0.0850)
0.082 2.12 2.12 2.14 2.14 2.16 2.16 2.18 2.18

(0.0835) (0.0835) (0.0843) (0.0843) (0.0850) (0.0850) (0.0858) (0.0858)
0.083 2.12 2.12 2.14 2.14 2.16 2.16 2.18 2.18 2.20 2.20
(0.0835) (0.0835) (0.0843) (0.0843) (0.0850) (0.0850) (0.0858) (0.0858) (0.0866) (0.0866)
0.084 2.12 2.12 2.14 2.14 2.16 2.16 2.18 2.18 2.20 2.20 2.22 2.22
(0.0835) (0.0835) (0.0843) (0.0843) (0.0850) (0.0850) (0.0858) (0.0858) (0.0866) (0.0866) (0.0874) (0.0874)
0.085 2.12 2.12 2.14 2.14 2.16 2.16 2.18 2.18 2.20 2.20 2.22 2.22 2.24 2.24 2.26
(0.0835) (0.0835) (0.0843) (0.0843) (0.0850) (0.0850) (0.0858) (0.0858) (0.0866) (0.0866) (0.0874) (0.0874) (0.0822) (0.0822) (0.0890)
0.086 2.12 2.12 2.14 2.14 2.16 2.16 2.18 2.18 2.20 2.20 2.22 2.22 2.24 2.24 2.26 2.26 2.28 2.28
(0.0835) (0.0835) (0.0843) (0.0843) (0.0850) (0.0850) (0.0858) (0.0858) (0.0866) (0.0866) (0.0874) (0.0874) (0.0882) (0.0882) (0.0890) (0.0890) (0.0898) (0.0898)
0.087 2.12 2.12 2.14 2.14 2.16 2.16 2.18 2.18 2.20 2.20 2.22 2.22 2.24 2.24 2.26 2.26 2.28 2.28 2.30 2.30
(0.0835) (0.0835) (0.0843) (0.0843) (0.0850) (0.0850) (0.0858) (0.0858) (0.0866) (0.0866) (0.0874) (0.0874) (0.0882) (0.0882) (0.0890) (0.0890) (0.0898) (0.0898) (0.0905) (0.0905)
0.088 2.14 2.14 2.16 2.16 2.18 2.18 2.20 2.20 2.22 2.22 2.24 2.24 2.26 2.26 2.28 2.28 2.30 2.30 2.32 2.32 2.34
(0.0843) (0.0843) (0.0850) (0.0850) (0.0858) (0.0858) (0.0866) (0.0866) (0.0874) (0.0874) (0.0882) (0.0882) (0.0890) (0.0890) (0.0898) (0.0898) (0.0905) (0.0905) (0.0914) (0.0914) (0.0921)
0.089 2.16 2.18 2.18 2.20 2.20 2.22 2.22 2.24 2.24 2.26 2.26 2.28 2.28 2.30 2.30 2.32 2.32 2.34 2.34 2.36 2.36
(0.0850) (0.0858) (0.0858) (0.0866) (0.0866) (0.0874) (0.0874) (0.0882) (0.0882) (0.0890) (0.0890) (0.0898) (0.0898) (0.0905) (0.0905) (0.0914) (0.0914) (0.0921) (0.0921) (0.0929) (0.0929)
0.090 2.18 2.20 2.20 2.22 2.22 2.24 2.24 2.26 2.26 2.28 2.28 2.30 2.30 2.32 2.32 2.34 2.34 2.36 2.36 2.38 2.38
(0.0858) (0.0866) (0.0866) (0.0874) (0.0874) (0.0882) (0.0882) (0.0890) (0.0890) (0.0898) (0.0898) (0.0905) (0.0905) (0.0914) (0.0914) (0.0921) (0.0921) (0.0929) (0.0929) (0.0937) (0.0937)
0.091 2.20 2.22 2.22 2.24 2.24 2.26 2.26 2.28 2.28 2.30 2.30 2.32 2.32 2.34 2.34 2.36 2.36 2.38 2.38 2.40 2.40
(0.0866) (0.0874) (0.0874) (0.0882) (0.0882) (0.0890) (0.0890) (0.0898) (0.0898) (0.0905) (0.0905) (0.0914) (0.0914) (0.0921) (0.0921) (0.0929) (0.0929) (0.0937) (0.0937) (0.0945) (0.0945)
0.092 2.24 2.24 2.26 2.26 2.28 2.28 2.30 2.30 2.32 2.32 2.34 2.34 2.36 2.36 2.38 2.38 2.40 2.40 2.42 2.42 2.44
(0.0882) (0.0882) (0.0890) (0.0890) (0.0898) (0.0898) (0.0905) (0.0905) (0.0914) (0.0914) (0.0921) (0.0921) (0.0929) (0.0929) (0.0937) (0.0937) (0.0945) (0.0945) (0.0953) (0.0953) (0.0961)
0.093 2.26 2.28 2.28 2.30 2.30 2.32 2.32 2.34 2.34 2.36 2.36 2.38 2.38 2.40 2.40 2.42 2.42 2.44 2.44 2.46 2.46
(0.0890) (0.0898) (0.0898) (0.0905) (0.0905) (0.0914) (0.0914) (0.0921) (0.0921) (0.0929) (0.0929) (0.0937) (0.0937) (0.0945) (0.0945) (0.0953) (0.0953) (0.0961) (0.0961) (0.0969) (0.0969)
0.094 2.28 2.30 2.30 2.32 2.32 2.34 2.34 2.36 2.36 2.38 2.38 2.40 2.40 2.42 2.42 2.44 2.44 2.46 2.46 2.48 2.48
(0.0898) (0.0905) (0.0905) (0.0914) (0.0914) (0.0921) (0.0921) (0.0929) (0.0929) (0.0937) (0.0937) (0.0945) (0.0945) (0.0953) (0.0953) (0.0961) (0.0961) (0.0969) (0.0969) (0.0977) (0.0977)
0.095 2.30 2.32 2.32 2.34 2.34 2.36 2.36 2.38 2.38 2.40 2.40 2.42 2.42 2.44 2.44 2.46 2.46 2.48 2.48 2.50 2.50
(0.0905) (0.0914) (0.0914) (0.0921) (0.0921) (0.0929) (0.0929) (0.0937) (0.0937) (0.0945) (0.0945) (0.0953) (0.0953) (0.0961) (0.0961) (0.0969) (0.0969) (0.0977) (0.0977) (0.0987) (0.0987)
0.096 2.34 2.34 2.36 2.36 2.38 2.38 2.40 2.40 2.42 2.42 2.44 2.44 2.46 2.46 2.48 2.48 2.50 2.50 2.52 2.52 2.54
(0.0921) (0.0921) (0.0929) (0.0929) (0.0937) (0.0937) (0.0945) (0.0945) (0.0953) (0.0953) (0.0961) (0.0961) (0.0969) (0.0969) (0.0977) (0.0977) (0.0987) (0.0987) (0.0992) (0.0992) (0.1000)
0.097 2.36 2.38 2.38 2.40 2.40 2.42 2.42 2.44 2.44 2.46 2.46 2.48 2.48 2.50 2.50 2.52 2.52 2.54 2.54 2.56 2.56
(0.0929) (0.0937) (0.0937) (0.0945) (0.0945) (0.0953) (0.0953) (0.0961) (0.0961) (0.0969) (0.0969) (0.0977) (0.0977) (0.0984) (0.0984) (0.0992) (0.0922) (0.1000) (0.1000) (0.1008) (0.1008)
0.098 2.38 2.40 2.40 2.42 2.42 2.44 2.44 2.46 2.46 2.48 2.48 2.50 2.50 2.52 2.52 2.54 2.54 2.56 2.56 2.58 2.58
(0.0937) (0.0945) (0.0945) (0.0953) (0.0953) (0.0961) (0.0961) (0.0969) (0.0969) (0.0977) (0.0977) (0.0984) (0.0984) (0.0992) (0.0922) (0.1000) (0.1000) (0.1008) (0.1008) (0.1016) (0.1016)
0.099 2.42 2.42 2.44 2.44 2.46 2.46 2.48 2.48 2.50 2.50 2.52 2.52 2.54 2.54 2.56 2.56 2.58 2.58
(0.0953) (0.0953) (0.0961) (0.0961) (0.0969) (0.0969) (0.0977) (0.0977) (0.0984) (0.0984) (0.0992) (0.0922) (0.1000) (0.1000) (0.1008) (0.1008) (0.1016) (0.1016)
0.000 2.44 2.46 2.46 2.48 2.48 2.50 2.50 2.52 2.52 2.54 2.54 2.56 2.56 2.58 2.58
(0.0961) (0.0969) (0.0969) (0.0977) (0.0977) (0.0984) (0.0984) (0.0992) (0.0922) (0.1000) (0.1000) (0.1008) (0.1008) (0.1016) (0.1016)
0.001 2.46 2.48 2.48 2.50 2.50 2.52 2.52 2.54 2.54 2.56 2.56 2.58 2.58
(0.0969) (0.0977) (0.0977) (0.0984) (0.0984) (0.0992) (0.0922) (0.1000) (0.1000) (0.1008) (0.1008) (0.1016) (0.1016)
0.002 2.48 2.50 2.50 2.52 2.52 2.54 2.54 2.56 2.56 2.58 2.58
(0.0977) (0.0984) (0.0984) (0.0992) (0.0922) (0.1000) (0.1000) (0.1008) (0.1008) (0.1016) (0.1016)
0.003 2.52 2.52 2.54 2.54 2.56 2.56 2.58 2.58

(0.0992) (0.0922) (0.1000) (0.1000) (0.1008) (0.1008) (0.1016) (0.1016)
0.004 2.54 2.56 2.56 2.58 2.58

(0.1000) (0.1008) (0.1008) (0.1016) (0.1016)
0.005 2.56 2.58 2.58

(0.1008) (0.1016) (0.1016)
0.006 2.58
(0.1016)
4. Place the shim (1) on the drive pinion, then install the 10. Install flange nut and washer.
inner bearing (2) onto the pinion by using installer 1. Apply lubricant to the pinion threads.
J–42828 and a press .
2. Using the pinion flange holder J–8614–01, tighten
NOTE: Do not apply pressure to the roller cage. Apply the nut only enough to remove the shaft end play.
pressure only to the inner race.
NOTE: Discard used flange nut and install new one.
425RW024
5. Install collapsible spacer. Discard the used 415RW006
collapsible spacer and install a new one. 3. Adjust pinion bearing preload.
6. Install drive pinion shaft assembly. a. Measure the bearing preload by using a torque
7. Install outer bearing and oil seal slinger. meter and note the scale reading required to
rotate the flange.
8. Use oil seal installer J–37263 to install a new oil seal
that has grease on seal lip. b. Continue tightening flange nut until the specified
starting torque is obtained.
Starting torque: 1.1–1.6 N·m (10–14 lb in)
NOTE:
a. Do not overtighten or loosen and then retighten the
nut.
b. Pinion nut torque should be in the range of
298–380 N·m (220–281 Ib ft).
425RS025
9. Install flange assembly.
425RW018
4. Using punch J–39209, stake the flange nut at two 2. Insert the differential cage assembly with bearing
points. outer races into the side bearing bores of the
carrier.
NOTE: When staking, be sure to turn the nut to ensure
that there is no change in bearing preload. Make sure of
preload again as instructed in 3).
425RS030
3. Using two sets of feeler gauges, insert a feeler

stock of sufficient thickness between each
425RS028
bearing outer race and the carrier to remove all
11. Adjust ring gear backlash.
end play. Make certain the feeler stock is pushed
1. Attach the side bearing to the differential to the bottom of the bearing bores.
assembly without shims by using installer
Mount the dial indicator J–8001 on the carrier so
J–42829 and grip J–8092.
that the indicator stem is at right angles to a tooth on
the ring gear.
425RW003
425RS031
4. Adjust feeler gauge thickness from side to side 12. Install the side bearings together with the selected
until ring gear backlash is in the specified range. shims by using installer J–42829 (2) and grip J–8092
(1).
Backlash: 0.13– 0.2mm (0.005– 0.008in)
425RW032
425RS032
13. Install side bearing outer race.
With zero end play and correct backlash
established, remove the feeler gauge packs, 14. Install differential cage assembly.
determine the thickness of the shims required and 15. Align the setting marks (1) applied at disassembly
add 0.05 mm (0.002 in) to each shim pack to then install the bearing cap.
provide side bearing preload. Always use new
shims.
5. Remove side bearing by using remover J–42379
and adapter J–8107–3.
425RS035
415RW003
16. Tighten the bolt to the specified torque.
Torque:108N·m (80lb ft)
425RS038
Legend
425RS036
(1) Heel
(2) Toe
(3) Concave Side(Coast)
Gear Tooth Contact Pattern Check and Adjustment (4) Convex Side(Drive)
1. Apply a thin coat of Prussian blue or equivalent to the
faces of the 7–8 teeth of the ring gear. Check the
impression of contact on the ring gear teeth and make
necessary adjustment as described in illustration if
the contact is abnormal.
425RS039
Differential Cage Assembly

Disassembled View
415RY00001
Legend (5) Ring Gear

(1) Pinion Mate Gear (6) Bolt
(2) Thrust Washer(for Side Gear) (7) Differention Cage
(3) Side Gear (8) Lock Pin
(4) Differential Shaft
Disassembly D Differential cage, carrier

D Thrust washer
1. Remove bolt.
D Oil seal
2. Remove ring gear.
Ring gear replacement:
3. Remove lock pin using a small drift.
1. The ring gear should always be replaced with the
drive pinion as a set.
locking agent.
3. Discard used bolts and install new ones.
4. When installing the ring gear, apply LOCTITE 271 or
equivalent to all the threaded area and half of the
unthreaded area of the bolt.
Torque: 127N·m (94 lb ft)
425RY00002
4. Remove the differential shaft by using a hard metal

rod and a hammer.
425RW033
Clearance between the differential pinion and the

pinion shaft measurement.
Standard: 0.07 – 0.13 mm (0.003 – 0.005 in)
Limit: 0.2 mm (0.008 in)
425RS043
5. Remove pinion mate gear and thrust washer.

6. Remove side gear and thrust washer.

D Ring gear, pinion gear
D Bearing
D Side gear, pinion mate gear, differential shaft 425RY00007
Clearance between the side gear and the differential Reassembly
box.
Differential cage
Standard: 0.032 – 0.105 mm (0.001 – 0.004 in) Thrust washer
Limit: 0.105 mm (0.004 in) Side gear
Pinion gear
1. Install the pinion gear by engaging it with the side
gears while turning both pinion gears simultaneously
in the same direction.
2. Install the pinion mate gear with thrust washer by
engaging it with the side gears while turning both
pinion mate gears simultaneously in the same
direction.
425RY00005
Legend
(1) Side gear
(2) Differential box
Play in splines between the side gear and the axle

shaft.
Standard: 0.07 – 0.38 mm (0.003 – 0.014 in) 425RS048
Limit: 0.5 mm (0.02 in) 3. Install differential shaft.

1. Be sure to install the differential shaft so that it is in
alignment with the lock pin hole in the differential
cage.
425RY00006
425RS049
2. Adjust the backlash between the side gear and 5. Install exciter ring (If equipped with rear wheel
the pinion gear. antilock).
Backlash: 0.15 – 0.20 mm (0.006 – 0.008 in) D Press the exciter ring on the differential cage using
the ring gear as a pilot.
Thickness of thrust washers available
NOTE: Discard used exciter ring and install new one.
mm 0.80 0.90 1.00 1.10 1.20 1.30
in 0.031 0.035 0.039 0.043 0.047 0.051
425RS052
6. Tighten the bolts in diagonal sequence as illustrated.

425RY00008
NOTE: Discard used bolts and install new ones.
4. Install lock pin.
D Install the lock pin using small drift.
425RW033
425RY00009
Limited Slip Differential

Disassembled View
425RY001
Legend (14) Pinion and Pinion shaft

(1) Screw (15) Side gear
(2) Differential cage A (16) Pressure ring
(3) Thrust washer (17) Friction Plate
(4) Spring disc (18) Friction disc
(5) Friction Plate (19) Friction Plate
(6) Friction plate (20) Friction disc
(8) Friction disc (22) Friction Plate
(10) Friction disc (24) Spring disc
(11) Friction Plate (25) Thrust washer
(12) Pressure ring (26) Differential cage B
(13) Side gear
Disassembly 9. Remove Friction plate.

Differential Cages A and B 10. Remove Friction disc.
1. To ensure installation of the parts in original position 11. Remove Friction plate.
apply a setting mark before removing the differential 12. Remove Friction disc.
cages A and B. 13. Remove Friction plate.
2. Using special tool, J–44450, grip it with a vice, and set 14. Remove Pressure ring.
the differential. 15. Remove Side gear.
16. Remove Pinion and pinion shaft.
17. Remove Side gear.
18. Remove Pressure ring.
19. Remove Friction plate.
20. Remove Friction disc.
27. Remove Thrust washer.
28. Remove Differential cage B.

425RS054 Make necessary correction or parts replacement if wear,
3. Gradually and evenly loosen the 3 fixing screws of the damage, corrosion or any other abnormal condition is
differential cages A and B. found through inspection.
Visual check
Check the following parts for wear, damage, noise or any
other abnormal conditions.
D Friction disc, friction plate and spring disc
425RS055
4. Remove Differential cage A.

5. Remove Thrust washer.
6. Remove Spring disc.
NOTE: When removing the spring disc, friction disc, and 425RS056
friction plate, place them in order for clear distinction of Legend

left and right use. (1) Sliding surfaces
7. Remove Spring disc. (2) Projections
D Pressure ring D Case
425RY003 425RS059
Legend Legend
(3) Sliding surface with the friction disc. When (11) Contact surface with the spring disc.
nicks or scratches are found, polish with an oil (12) Inner groove of the differential cage B.
stone and repair on a level block using a Repair light nicks and burrs using an oil stone.
compound.
(4) Sliding spherical surface with the pinion gear.
(5) Sliding surface with the side gear.
(6) V–shaped groove of the pressure ring and V
–shaped section of the pinion shaft.
(7) Fitting section with the case.
(8) Face contacting the inner surface of the
differential case. Repair burrs and nicks using
an oil stone.
D Thrust washer
425RS060
Legend
(7) Fitting section with the case.
(8) Face contacting the inner surface of the
differential case.
Repair burrs and nicks using an oil stone.
(9) Sliding surface with the side gear or case.
(11) Contact surface with spring disc.
425RS058
Legend
(9) Sliding surface with the side gear or case.
(10) Peripheral groove of the side gear.
Repair light nicks and burrs using an oil stone.
Measure the Deformation of the friction disc & plate. Measure the wear of the thrust washer
Limit: 0.1 mm (0.004 in) Limit: 1.3 mm (0.05 in)
425RS061 425RS063
Measure the wear of the friction plate & disc

Limit(A–B): 0.1 mm (0.004 in) Reassembly
Remarks:
A=Inner or outer projections Adjust the clearance between the friction disc and plate.
B=Sliding surface subjected to abrasion 1. Measuring the depth of the differential cage.
Standard (A–B): 89.13 mm (3.51 in)
(C): 9.13 mm (0.36 in)
425RS062
425RS064
2. Measuring the overall length of the pressurering,
friction disc and friction plate.
D Mount the pinion shaft in the pressurering and then
install the friction disc & plate.
D Measure the length between the plates over the
V–groove. (D)
425RS066
2. Measuring the dimension between the thrust washers

at both ends.
D Assemble the side gear, pinion, pinion shaft,
pressure ring and thrust washer, and pressing the
pressure ring to–the pinion shaft in the direction of
the shaft to make the clearance 0.
D Have the side gear contact to the pinion to make the
425RS065
3. After measuring dimensions A,B,C and D, make

backlash 0.
adjustment in the following manner:
D Measure the thickness (E) of the spring disc. D Measure the dimension (H) between thrust
1.75mm (0.069in) ×2 discs washers at both ends.
4. Select the friction disc & plate so as to satisfy the
following equation:
{(A-B)+C}-(D+E)=0.06-0.20mm (0.002-0.008in)
Also, the total size difference of the friction disc &
plate and spring disc should be 0.05mm (0.02in) or
less.
Thickness
:1.65–1.75–1.85mm(0.065–0.069–0.073 in)
Backlash adjustment of the side gear in

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

425RS055
28. Check the operation.
D Measure the starting torque using the side gear
holder.
Starting torque:
29 – 45 N·m (3.0 – 4.6 kg·m/ 22 – 33Ib ft)
425RW065
Legend
(1) Side Gear Holder : J–44450

Rear axle
Type Banjo, Semi–floating
Rear axle Size 244 mm (9.61 in)
Gear type Hypoid
Gear ratio (to 1) 4.300
Differential type Two pinion
Lubricant Grade GL–5: (Standard differential)
GL–5, LSD: (Limited slip differential)
Locking Differential Lubricant 80W90 GL–5
(USE Limited Slip Differential Gear Lubricant or Friction
Modifier Organic Additive)
Capacity 3.0 liter (3.2 US qt)
420RY00002
Special Tools
TOOL NO. TOOL NO.
TOOL NAME TOOL NAME
J–39210
J–37263
Installer; Axle shaft inner
Installer; Pinion oil seal
seal
J–6627–A J–42832
Wheel pin remover Holding fixture
J–39211
J–3289–20
Remover; Axle shaft
Holding fixture base
bearing
J–39212
J–42379
Installer; Axle shaft
Remover; Bearing
bearing
J–8107–3
J–39379
Adapter; Side bearing
Installer; Outer axle seal
plug
J–44461
J–8614–01
Installer; Outer bearing
Pinion flange holder
outer race
TOOL NO. TOOL NO.

TOOL NAME TOOL NAME
J–8092 J–44451
Grip Gage plate
J–44462
J–8001
Installer; Inner bearing
Dial indicator
outer race
J–42824 J–44452
Pilot;Outer Disc (2 required)
J–21777–43 J–23597–1
Nut & Stud Arbor
J–44453 J–42828
Pilot;Inner Installer; Pinion bearing
J–44449 J–39209
Pilot;Outer bearing Punch; End nut lock
TOOL NO.
ILLUSTRATION
TOOL NAME
J–42829
Installer; Side bearing
J–39602
Remover; Outer bearing
J–39858
Clutch pack unloading
tool kit Includes
J–34174–1/J–34174–2
Screw cap and Cap
J–22342–15
Forcing screw
J–44450
Side gear holder
DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY) 4B1–1
TROOPER
DRIVELINE/AXLE
DRIVELINE CONTROL SYSTEM (SHIFT ON THE FLY)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 4B1–1 Vacuum piping diagram . . . . . . . . . . . . . . . . . . 4B1–19
Shift On The Fly System . . . . . . . . . . . . . . . . . 4B1–2 Inspection And Repair . . . . . . . . . . . . . . . . . . . 4B1–20
Outline of Shift on The Fly System . . . . . . . . . 4B1–2 4WD Control Unit . . . . . . . . . . . . . . . . . . . . . . . 4B1–23
Functions of Indicator Lamp . . . . . . . . . . . . . . 4B1–6 4WD Control Unit Associated Parts . . . . . . 4B1–23
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B1–7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B1–24
Front Axle Diagnosis . . . . . . . . . . . . . . . . . . . . . 4B1–17 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B1–24
Shift On The Fly Vacuum Piping And
Electric Equipment . . . . . . . . . . . . . . . . . . . . . . 4B1–19
Service Precaution
systems.
4B1–2 DRIVE LINE CONTROL SYSTEM (SHIFT ON THE FLY)
Shift On The Fly System
Outline of Shift on The Fly System

The shift on the fly system switches between 2 wheel
drive (2WD) and 4 wheel drive (4WD) electrically by
driver’s pressing the 4WD switch (push button type) on
instrument panel.
This system controls below operations. (Shifting between
“4H” and “4L” must be performed by transfer control lever
on the floor.)
1. Shifting the transfer front output gear (Connecting to,
and disconnecting from, front propeller shaft by motor
actuator).
2. Retrial of shifting the transfer front output gear.
3. Connecting front wheels to, and disconnecting them
from, the front axles by vacuum actuator.
4. Indicator on instrument panel.
5. 4WD out signal to other Electronic Hydraulic Control
Unit.
System Diagrams
412RX003
Normal Operation
The motor actuator mounted on transfer rear case is of the transfer position switch changes. The vacuum
driven by signal from 4WD switch on instrument panel. solenoid valve (VSV) is driven by the signal from transfer
After complete the connecting transfer front output gear position switch and the vacuum actuator connects front
to, or disconnecting it from, front propeller shaft, condition wheels to, or disconnect them from, front axles.
Time Chart of Shifting Under Normal Condition
F04RW002
Retrial
The motor actuator starts transfer gear shifting after gear. This procedure is repeated 3 times in maximum.
signal from 4WD switch on instrument panel has been While this procedure, 4WD indicator lamp blinks by 2 Hz.
received. But the shifting may be impossible in cold If the transfer position switch does not turn on after
weather or under high speed condition. When 2 seconds aforementioned procedure has been repeated 3 times,
have passed since transfer gear shifting started and the the gear shifting is stopped and 4WD indicator lamp’s
transfer position switch dose not turn on (the gear blinking changes from 2Hz to 4Hz to notify driver that the
engagement is not completed), the motor reverses its gear shifting is stopped. This blinking of indicator lamp
rotation for 1.2 seconds and tries again to shift transfer continues until 4WD switch is returned from 4WD to 2WD.
Time Chart of Shifting Under Severe Condition (retrial)
F04RX001
Warning at “4L” position :In view of the shifting switch when vehicle is in “4L” condition. In the case this
mechanism of transfer, the gear shifting from 4WD to condition continues for 2 seconds, the shifting to 2WD is
2WD at “4L” condition is impossible. Therefore, the stopped and the indicator lamp’s blinking changes from
transfer position switch can not be turned off by 4WD 2Hz to 4Hz to notify driver of wrong operation.
Time Chart of Shifting from 4WD to 2WD at “4L” Condition
F04RX002
4WD out signal to other Electronic Hydraulic Control

Unit : 4WDcontrol unit sends 4WD out signal to other
Electronic Hydraulic Control Unit as below.
4WD out signal Vehicle Condition Transfer position switch Front axle switch
(Period)
120 ms 2WD 2WD (Open) 2WD (Open)
240 ms 4WD 4WD (Close) 4WD (Close)
Functions of Indicator Lamp

Indication of vehicle condition : Indicator lamp is
controlled by 4WD control unit and shows vehicle
conditions as below.
Indicator Vehicle condition 4WD switch Transfer position Front axle switch
switch
Off 2WD Off (Close) 2WD (Open) 2WD (Open)
On 4WD On (Open) 4WD (Close) 4WD (Close)
Blink (2Hz) Operating On (Open) 4WD (Close) 2WD (Open)
Off (Close) 2WD (Open) 4WD (Close)
Blink (4Hz) Stop operating On (Open) 2WD (Open) 2WD (Open)
Off (Close) 4WD (Close) 4WD (Close)
Bulb check :
F04RX003
Retrials from 2WD to 4WD :In cold weather or under

high speed condition, the gear shifting (engagement)
sometimes does not complete by 3 trials. In such case,
the indicator lamp inform driver of this incident as
aforementioned chart (shown at Retrial in Outline of shift
on the fly system).
Diagnosis
Before Judging That Troubles Occur When switching from 4WD to 2WD
(Unfaulty mode) 1. In case that the 4WD indicator continues blinking
When Switching from 2WD to 4WD by 2Hz .
The 4WD indicator continues blinking by 2Hz until
1. In case that blinking frequency of the 4WD both shifting the transfer gear and disconnecting the
indicator changes from 2Hz to 4Hz. front wheels are completed when switching 4WD to
When heavy synchronization load is needed, the 2WD. When driveline is loaded with torsional torque,
motor actuator tries the shifting transfer gear three the shifting transfer gear and disconnecting front
times including the activation shifting. While the wheels are impossible. In this case, removal of
motor actuator tries shifting, the indicator blinks by torsional torque on driveline make the shifting
2Hz. If the third shifting fails, the indicator’s blinking transfer gear and disconnecting front wheels
changes from 2Hz to 4Hz at the same time that the possible.
motor actuator shifted back to 2WD. Solution 3: When vehicle is running, drive
Heavy synchronization load occurs by: straight ahead while accelerating and
D extremely lower temperature. decelerating. When vehicle is at a stop, move the
vehicle forward and backward from 2 to 3 meters.
D higher speed, rotation difference of wheels during
cornering. 2. In case that the 4WD indicator’s blinking changes
from 2Hz to 4Hz.
Solution 1: Operate again after stop the vehicle or
slow down. Check the position of transfer lever. Is it at “4L”
position? In view of the shifting mechanism of
2. In case that the 4WD indicator continues blinking transfer, the gear shifting from 4WD to 2WD at “4L”
by 2Hz for more than 11.5 seconds. condition is impossible.
When there is rotation difference of wheels or there Solution 4: Push the 4WD switch to 4WD, shift the
is phase difference between front wheels and axles, transfer lever to “High” position and re–operate
it is difficult to connect front wheels to front axles. The the 4WD switch to 2WD.
blinking by 2Hz shows that shifting the transfer gear
or connecting the front wheels is in the middle of
operating. In above case, the indicator’s blinking by
2Hz shows that connecting the front wheels is not
completed (because the indicator’s blinking changes
to 4Hz when the shifting transfer gear is impossible.).
And removal of rotation or phase difference make
connecting the front wheels possible.
Solution 2: When vehicle is running, drive
straight ahead while accelerating and
decelerating. When vehicle is at a stop, move the
vehicle forward and backward from 2 to 3 meters.
Parts Location
D08RX005
Legend (8) M–22

(1) I–12 (9) M–23
(2) I–9 (10) M–24
(3) H–7, H–24, H–25 (11) H–10
(4) Fuse Box (12) M–26
(5) C–16 (13) Relay & Fuse Box
(6) C–94 (14) H–12, H–16
(7) M–11, M–12
Wiring Diagram
D08RW028
D08RW029
Connector List
D04RW030
Diagnosis of The Faults Based on the
Status of 4WD Indicator Lamp, 4WD
Switch and T/F Change Lever
Diagnosis charts are shown on below. If troubles can not
be solved after every chart was traced, troubles may
occur in the 4WD control unit. In this case, replace the
4WD control unit and trace every chart again.
Fault on switching from 2WD to 4WD
1. In case that 4WD indicator’s blinking changes
from 2Hz to 4Hz after Solution 1 is carried out.
Faults occur in the motor actuator or the transfer case
assembly. Remove the motor actuator and check
function. If problem was found and it was repaired, try
Solution 1 again. After that, disassemble the
transfer case assembly for check and repair or
replace. If incident is not improved after above
mentioned actions were taken, replace the 4WD
control unit.
2. In case that 4WD indicator does not blink nor
light, when switching from 2WD to 4WD.
Step Action Yes No
1 Is ignition turned on? Turn on the
ignition and trace
this chart from
Go to Step 2 start.
2 Burning out of
indicator lamp or
Does the indicator light comes on when the engine is not started?
disconnection of
harness wire.
Trace this chart
from the start
after repair or
Go to Step 3 replace.
3 Start the engine. Short-circuit
(body short) on
Is the 4WD switch turned from 2WD to 4WD?
harness of the
4WD switch.
Fault of the 4WD
switch (holding
the closed
condition).
Trace this chart
from the start
after repair or Push the 4WD
replace. switch to 4WD.
3. Case that the indicator keeps blinking by 2Hz
after aforementioned Solution 2 is carried out.
Step Action Yes No
1 Check the air pressure and wear of all tires. Try Solution 2
after adjust the
Were problems found?
air pressure and
replace worn
tires. Go to Step 2
2 Disconnection of
the motor
Can the transfer lever be operated from High to 4L or vice versa?
actuator harness
wiring. Trace this
chart from the
start after repair
or replace.
Faults on the
motor actuator.
Trace this chart
from the start
after replace.
Internal faults of
transfer case.
Disassemble the
transfer case for
check. Trace this
chart from the
start after repair
Go to Step 3 or replace.
3 Pull out the hoses from vacuum actuator and operate 4WD Faults on the
switch. transfer position
switch or its
Is there negative pressure on either of hoses?
harness. Trace
this chart from
the start after
repair or replace.
Faults on the
VSV main body,
its harness or
vacuuming
system. Trace
the front axle
diagnosis chart in
this section.
After that, trace
this chart from
Go to Step 4 the start.
4 Check the axle switch. Disconnection on
the axle harness.
Trace this chart
from the start
after repair or
replace.
Faults on Front
Axle ASM. Trace
the front axle
Internal faults on diagnosis chart in
axle switch. this section.
Trace this chart After that, trace
from the start this chart from
after replace. the start.
Fault on switching from 4WD to 2WD
1. Case that indicator does not blink nor turn out.
Step Action Yes No
1 Short circuit of
the indicator
Does the indicator turn out by ignition off?
Go to Step 2 harness.
2 Disconnection on
the 4WD switch
Is the 4WD switch on 2WD position?
harness or
breakdown of the
4WD switch in
open state. Turn the 4WD
Trace this chart switch to 2WD
from the start position. Trace
after repair or this chart from
replace. the start.
2. Case that indicator keeps 2Hz blinking after
aforementioned Solution 3 is carried out.
Step Action Yes No
1 Check the air pressure and wear of all tires. Try Solution 3
after adjust the
air pressure and
replace worn
tires. Go to Step 2
2 Faults on the
harness wiring of
motor actuator.
Trace this chart
from the start
after repair or
replace.
Internal faults on
transfer case.
Disassemble the
transfer case for
check. Trace this
chart from the
start after repair
or replace.
Faults on the
motor actuator.
Trace this chart
from the start
after or replace. Go to Step 3
3 Pull out the hoses from vacuum actuator and operate 4WD Faults on the
switch. transfer position
switch or its
Is there negative pressure on either of hoses?
harness. Trace
this chart from
the start after
repair or replace.
Faults on the
VSV main body,
its harness or
vacuuming
system. Trace
the front axle
diagnosis chart in
this section.
After that, trace
this chart from
Go to Step 4 the start.
4 Check the axle switch. Internal faults on
axle switch.
Trace this chart
from the start
after replace.
Faults on Front Short circuit
Axle ASM. Trace (body short) or
the front axle disconnection of
diagnosis chart in the axle harness.
this section. Trace this chart
After that, trace from the start
this chart from after repair or
the start. replace.
3. Case that indicator’s blinking changes to 4Hz
after aforementioned Solution 4 is carried out.
Step Action Yes No
1 Faults on the
harness wiring of
motor actuator.
Trace this chart
from the start
after repair or
replace.
Faults on the
motor actuator.
Trace this chart
from the start
after replace.
Internal faults on
transfer case.
Disassemble the
transfer case for Faults on the
check. Trace this 4WD control unit.
chart from the Trace this chart
start after repair from the start
or replace. after replace.
Front Axle Diagnosis

D When the 4WD switch is operated from 4WD to 2WD,
indicator light does not go out.
Step Action Yes No
1 Drive slow 100 — 200m after a few minutes” idling.
Has indicator light gone out? All right. Go to Step 2
2 Jack up front tires.
Does the right side of front wheel rotate when the left side of front
wheel is rotated? Go to Step 4 Go to Step 3
3 1. Check the actuator switch. Disassemble axle
2. Check the circuit to indicator. ASM for check.
Trace this chart Trace this chart
Was a problem found?
from the start from the start
after repair or after repair or
replace. replace.
4 1. Check the VSV valve. Trace this chart
2. Check the circuit to VSV valve. from the start
after repair or
replace. Go to Step 5
5 Is vacuum piping all right? (tank, hose, & pipe damage or trouble) Trace this chart
from the start
after repair or
6 Does actuator work all right? Disassemble axle
ASM for check.
Trace this chart
from the start
Trace this chart after repair or
from the start. replace.
D When the 4WD switch is operated from 2WD to 4WD,
indicator light is not actuated.
Step Action Yes No
1 Drive slow 100 — 200m after a few minutes” idling.
Has indicator light actuated? All right. Go to Step 2
2 Jack up front tires.
Does not the right side of front wheel rotate when the left side of
front wheel is rotated? Go to Step 4 Go to Step 3
3 1. Check the actuator switch. Disassemble axle
2. Check the circuit to indicator. ASM for check.
Trace this chart Trace this chart
from the start from the start
after repair or after repair or
replace. replace.
4 1. Check the VSV valve. Trace this chart
2. Check the circuit to VSV valve. from the start
after repair or
replace. Go to Step 5
5 Is vacuum piping all right? (tank, hose, & pipe damage or trouble) Trace this chart
from the start
after repair or
6 Does actuator work all right? Disassemble axle
ASM for check.
Trace this chart
from the start
Trace this chart after repair or
from the start. replace.
Shift On The Fly Vacuum Piping And Electric Equipment
Vacuum piping diagram
C04RW007
VSV Assembly, Actuator Assembly Vacuum Tank
412RS032 412RS033
Inspection And Repair

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

Inspect the vehicle side harness as follows: A – B:There is continuity
C:Closed
3. If 1) and 2) fail, replace with a new VSV.
Axle Position Switch
412RS071
Legend
(1) Grey
(2) Blue
412RS048
1. Remove connector. 1. With ball (1) being free

2. Shift transfer lever to 2H and start the engine. A – B:There is continuity
NOTE: Do not move the vehicle while inspection. 2. With ball forced into the switch
3. Make sure that there is continuity in the vehicle side of A – B:No continuity
harness. If there is no continuity, check transfer shift 3. If 1) and 2) fail, replace with a new switch.
switch and wiring.
Inspect both VSVs as follows: Motor Actuator Assembly
Inspect the function of the motor actuator assembly as
follows:
F04RS004
1. With battery not connected (Usual).

A–C:There is continuity
B:Closed
1. Disassemble the motor actuator from transfer rear Shift rod of the motor actuator moves and stops
case. at 2WD position.
412RW037 412RX002
Legend Legend
(3) Shift Rod (1) 2WD
(4) Connector (2) 4WD
(3) Shift Rod
2. Connect the terminals as shown in figure. (4) Connector
Shift rod of the motor actuator moves and stops
at 4WD position. 4. If 2) and 3) fail, replace with a new motor actuator.
Transfer Position Switch
412RX001
Legend
(1) 2WD 412RW040
(2) 4WD Legend

(3) Shift Rod (1) Ball
(4) Connector
1. With ball being free.
3. Connect the terminals as shown in figure. A–B : There is continuity.
2. With ball forced into the switch.
A–B : No continuity.
3. If 1) and 2) fail, replace with a new switch.
4WD Control Unit

4WD Control Unit Associated Parts
412RW044
Legend (3) Harness Connector

(1) Lower Cluster Assembly (4) Nut
(2) Front Console Assembly (5) 4WD Control Unit
Removal
1. Remove lower cluster assembly and front console
assembly.
Refer to Interior Trim in Body and Accessories
section.
2. Remove nut.
3. Remove 4WD control unit.
4. Disconnect harness connector (1).
412RW045
Legend
(1) Harness Connector
Installation
1. Connect harness connector, then install 4WD control
unit.
2. Install lower cluster assembly and front console
assembly.
DRIVE LINE CONTROL SYSTEM (TOD) 4B2–1
TROOPER
DRIVELINE/AXLE
DRIVELINE CONTROL SYSTEM (TOD)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 4B2–1 Connector List . . . . . . . . . . . . . . . . . . . . . . . . . . 4B2–20
General Description . . . . . . . . . . . . . . . . . . . . . 4B2–2 Checking Failed Pin . . . . . . . . . . . . . . . . . . . . . 4B2–22
System Components . . . . . . . . . . . . . . . . . . . . 4B2–4 Checking Failed TOD Control Unit Pin . . . . . 4B2–25
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 4B2–4 Tech 2 Scan Tool . . . . . . . . . . . . . . . . . . . . . . 4B2–26
Functions of Indicator Lamp . . . . . . . . . . . . . . 4B2–8 Diagnostic Trouble Codes . . . . . . . . . . . . . . . . 4B2–29
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B2–11 Diagnosis from Trouble Codes . . . . . . . . . . . . 4B2–30
Basic Diagnostic Flow Chart . . . . . . . . . . . . . . 4B2–15 Trouble Diagnosis Depending on The Status
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . . . 4B2–16 of TOD Indicator . . . . . . . . . . . . . . . . . . . . . . . . 4B2–54
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 4B2–17 Diagnosis from Symptom . . . . . . . . . . . . . . . . . 4B2–83

systems.
4B2–2 DRIVE LINE CONTROL SYSTEM (TOD)
General Description
C07RY00003
TOD (Torque on Demand) system is traction state control

system to vehicle.
Transfer Position and Drive Mode
Three drive modes can be selected through operation of
4WD switch and transfer lever.
Transfer Position 4WD AUTO Mode Drive mode
SWITCH
HIGH ON 2H Rear wheel drive
OFF TOD Electronically controlled torque split
four wheel drive
4L ON/OFF 4L Low-speed mechanical lock-up four
wheel drive
The electronic control unit (ECU) judges the signals from unit. The pressing force of the clutch is controlled by
the transfer lever and controls the transfer drive mode changing the voltage to the electromagnetic coil mounted
and shift-on-the-fly system status. to the rear of the clutch. When the clutch is completely
disengaged, the rear wheels are driven. When the clutch
TOD Control is completely engaged, a rigid four wheel drive mode is
The TOD position usually drives the rear wheels, and obtained. The torque split status is controlled
transmits the torque to the front wheels with the help of continuously between the rear wheel and four wheel drive
electronically controlled torque split mechanism modes. This system includes front and rear speed
according to running conditions encountered. The driving sensors, and receives throttle position sensor information
force is directly transmitted to the rear wheels. This force from the PCM.
is split by the transfer and delivered to the front wheels. The control unit receives signals sent from these sensors
The magnitude of the torque transmitted to the front and changes the pressing force of the electromagnetic
wheels is controlled by changing the pressing force of the multi plate disk clutch to determine the torque distribution
electromagnetic multi plate disk clutch built in the transfer on the front and rear wheels. Therefore, when the slip of
the rear wheels is increased against the current torque
level in the normal rear wheel drive mode, the control unit
detects the slip condition, determines the optimum torque
based on the feedback control logic, and increases the
torque to the front wheels.
The control unit uses the signal from the throttle position
sensor to predict the future vehicle condition and the
intention of the driver with respect to acceleration and
deceleration, and determines the initial torque distribution
using these data and the information from the speed
sensors.
In case of small circle turning in the parking lot, for
example, the control unit minimizes the clutch pressing
force to restrict a braking phenomenon. When the ABS
becomes active, the control unit optimizes the clutch
pressing force to ensure stable braking.
TOD Indicator Control

The TOD indicator on the instrument panel informs the
driver of the current working status of the transfer unit.
The information consists of two items: the drive mode
(2H, TOD, 4L, transition) and the torque split status of the
TOD (torque distribution level). The indicator can display
occasional errors and corresponding error codes.
System Components
Parts Location
A07RY00002
Legend (5) Multi Plate Disk Clutch Pack

(1) T/F Connector (6) Electromagnetic Coil
(2) 4H Switch and 4L Switch (7) Rear Speed Sensor
(3) High-Low Planetary Gear Set (8) Front Speed Sensor
(4) Mechanical Lock
Front and Rear Speed Sensors Multi Plate Disk Clutch Pack
The sensors are built in the transfer case, and detect the Transmits the torque determined by the clutch pressing
rotation of rotors directly coupled to the propeller shafts. force to the front propeller shaft via the front drive chain.
Thirty rectangular pulses are output per one rotation of
the propeller shaft.
262RW029
261RW045
Mechanical Lock Sleeve
Couples the front and rear propeller shaft mechanically
Electromagnetic Coil when the transfer shaft is in the 4L position.
Receives the duty signals from the TOD control unit and
controls the pressing force of the clutch pressure cam.
262RW028
261RW044
High-Low Planetary Gear Set Transfer Connector
Establishes an auxiliary transmission mechanism. When Transmits the input and output signals of the speed
the transfer shift lever is set to the 2H or TOD position, the sensors, electromagnetic coil, and 4H and 4L switche to
reduction gear ratio is 1.000 and the corresponding the vehicle harness. A waterproof 12-pin type is used.
driving force is generated. When the transfer shift lever is
set to the 4L position, the reduction gear ratio is 2.480 and
the corresponding driving force is generated.
261RW046
TOD Indicator Lamps (on the instrument

262RW030 panel)
Inform the following items.
4H and 4L Switch D Bulb check
Detects the shift position of the transfer from the
D Drive mode
movement of the transfer lever and outputs signals to the
TOD control unit. D ABS IN status
D BRAKE ON status
261RW002
821RW049
Check Lamp
Inform the following items.
D Bulb check
D Fail (fail alarm)
D Trouble code
821RW078
TOD ECU
This control unit is mounted to the front right hand seat via
a special bracket.
F07RW029
Functions of Indicator Lamp

TOD Indicator Lamps
C07RY00017
Indication of Drive Mode NOTE: After the transfer lever is set to the specified
The transfer lever position signals are transmitted to the position and the AXLE switch generates compliant
TOD indicator lamp control unit according to the signals, the normal output status is returned.
conditions listed below.
Indication During Transition of Transfer Lever
When the transfer lever is shifted, and the signals from
the AXLE switch do not comply with the signal conditions
of the 4H and 4L switch, the transfer lever position signals
generated by the 4H and 4L switch and the N position
signals are repeatedly output at an interval of 0.8 second.
C07RW015
Bulb Check
When the starter switch is turned on, the TOD indicator
lamps go on as shown below.
NOTE: Once the starter switch is turned on, all the TOD
indicator lamps are lit for two seconds even if the transfer
lever is in any position.
C07RW016
Simplified checking method of ABS IN and BRAKE ON signals:
In the event that any of the signal inputs listed below are
observed while the self-diagnostic code is being
displayed (the self-diagnostic connector is short-circuited
to GND), you can simply check the ABS IN and BRAKE
ON signals as shown in the figures below.
C07RW017–1
Check Lamp
Check Lamp Bulb Check
When the starter switch is turned on in the normal state,
the control unit turns on the CHECK lamp to check the
bulb.
C07RW019
Diagnosis
General Information Diagnosis
The troubles on TOD are classified into the group that can
be identified by the lighting status of the TOD indicator
lamps and those that can be recognized as abnormal
phenomena of the vehicle by the driver.
The troubles that can be identified by the lighting status of
the TOD indicator lamps are examined by the procedures
“Diagnosis from Trouble Codes” and “Trouble Diagnosis
Depending on The Status of TOD Indicator”. The troubles
that can be recognized as abnormal phenomena of the
vehicle by the driver are examined by the procedure
“Diagnosis from symptom”.
Self-diagnosis
The control unit has a function of self-diagnosis. If a
trouble occurs in the course of system startup, the control
unit blinks the CHECK lamp and saves the trouble code.
C07RW021
NOTE: If an intermittent fault occurs, the control unit

stops blinking upon removal of the fault. The trouble code
is saved to the control unit.
Indication Method of Trouble Code D If no trouble codes exist, code “12” is displayed
D Short-circuit terminal 8 of the self-diagnostic continuously.
connector to GND to display the trouble code on the D If trouble codes exist, code “12” is displayed three
CHECK lamp. times, and the trouble codes, starting from the smaller
code number, are displayed three times respectively.
821RW021
C07RY00018
How to Clear The Trouble Code Trouble Intermittently Observed
The trouble codes saved to the control unit can be deleted Troubles intermittently observed are mostly attributable
by the following procedure if the starter switch is being in to temporary imperfect connection of harnesses and
the OFF position. connectors.
1. Shift the transfer lever to the neutral position between When such troubles are found, check the associated
HIGH and 4L, and short-circuit the self-diagnostic circuit according to the following procedure.
connector. 1. Check whether improper connectors are plugged in
NOTE: The neutral position between HIGH and 4L refers or connector terminals are completely engaged.
to the point that turns off the TOD indicator lamps. 2. Check whether the terminals are deformed or
(However, be sure to check the position before damaged. If yes, remove the deformation or damage
short-circuiting the self-diagnostic connector.) and connect the terminals securely.
3. It is likely that wires in the harness are falsely broken.
Therefore, in examination of failed harness circuit,
shake the harness for check to such extent that the
harness will not be damaged.
Test Run of Failed TOD Vehicle
If the TOD indicator lamps experienced faulty operation
even once in the past, the failed portion can be identified
by use of the procedure “Diagnosis from Trouble Codes”
or “Diagnosis from Lighting Status of TOD Indicator
Lamps”. If the troubles that are only recognized as
abnormal phenomena of the vehicle by the driver are
observed, conduct the test run in the following procedure
to reproduce the faulty phenomena and diagnose the fault
for each phenomenon.
1. Start the engine, and check that the TOD indicator
lamps are turned on for about two seconds for initial
check; the CHECK lamp goes off; and the TOD
indicator lamps display the specified drive mode. (If
the CHECK lamp starts blinking, read the trouble
C07RW011 codes and identify the failed portion.)
2. Turn on the starter switch while maintaining the state 2. While keeping the vehicle standstill, operate the 4WD
of step 1, and step on the brake pedal five times within switch and shift the transfer lever to change the
five seconds from the first step on. (Note that “five modes: 2H mode→TOD mode→4L mode→TOD
times” includes the first step on). (The TOD indicator mode→2H mode. Check that the TOD indicator
lamps display the 4L mode whenever the brake pedal lamps correctly display the status whenever the
is stepped on.) mode is changed. If the transition status is displayed
3. If the conditions shown in steps 1 and 2 are met, clear during the shift operation, run the vehicle a little to
the trouble codes saved to the control unit. (After the complete shifting.
codes are completely deleted, the code 12 that 3. Slowly start the vehicle in the TOD mode, and add the
indicates the normal condition is continuously power to accelerate to at least 40 km/h and maintain
displayed.) the speed for about two minutes. Apply the brake to
completely stop the vehicle. Repeat this test pattern
Precautions on Diagnosis at least three times.
Replacement of Control Unit 4. Turn the steering to the right end (or left end) in the
The control unit itself rarely fails. In most cases, the TOD mode, and slowly start the vehicle and make a
harnesses have failed (i.e. short-circuit) to cause circle five times. Next, conduct the same test in the 2H
secondary troubles. Other cases include that the cause mode.
has been unknown due to intermittent occurrence of 5. Slowly start the vehicle in the TOD mode, and
troubles and the troubles are removed accidentally along accelerate to at least 40 km/h. Keep the established
with replacement of control unit, resulting in misjudgment speed, carefully change the mode in the sequence
of cause. Therefore, before replacing the control unit, “TOD mode→2H mode →TOD mode” while checking
check the connector joints and whether the unspecified that the shift is complete in each mode change. After
current flows in the control unit due to short-circuit the test, apply the brake to completely stop the
between harnesses. vehicle.
6. Slowly start the vehicle in the TOD mode, and
accelerate to at least 40 km/h. Apply the brake
strongly so that the ABS works, and completely stop
the vehicle.
7. Slowly start the vehicle in the 4L mode, and
accelerate to at least 20 km/h. Apply the brake to
completely stop the vehicle.
If the CHECK lamp starts blinking during the test run, read
the trouble codes and give appropriate maintenance
according to the diagnostic procedure. If the TOD
indicator lamps are lit abnormally during the run, check
the lighting condition and give appropriate maintenance
according to the diagnostic procedure. Even if the
phenomena are not observed, try to reproduce the
abnormal state reported by the customer to the possible
extent.
Post-Repair Check
As long as the starter is not turned off, the TOD indicator
lamps continue blinking even after the failed control unit is
repaired. Therefore, upon completion of repair, be sure to
turn off the starter switch once and then turn on it to
conduct the test run sequence specified in steps 1
through 6 above and check that the TOD indicator lamps
no longer show any faulty status.
Basic Diagnostic Flow Chart
C07RW023–1
Parts Location
D08RW367
Legend (11) M–24

(1) I–9 (12) H–10
(2) C–63 (13) H–17
(3) H–7, H–8, H–25 (14) E–54
(4) H–33 (15) E–29
(5) Fuse Box (16) Relay & Fuse Box
(6) C–16 (17) H–12
(7) B–13 (18) B–48, B–49
(8) H–55, H–57 (19) H–33, H–36
(9) M–22 (20) M–27
(10) M–23 (21) I–12
Circuit Diagram
D04RY00003
D04RY00002
D04RY00010
Connector List
No. Connector face No. Connector face
B-13 H-8
B-48 H-10
B-49 H-12
C-16 H-17
C-63 H-25
C-94 H-33
E-29 H-36
E-54 H-55
H-7 H-57
No. Connector face

I-9
I-12
M-22
M-23
M-24
M-27
Checking Failed Pin

Connector Pin Assignment
D ECU pin assignment
D04RY00011
No. NAME CONTENTS

1 N.C Not used
2 N.C Not used
3 N.C Not used
4 D–G MAP Gas/Diesel
5 N.C Not used
6 IND. b Display Front–B
7 N.C Not used
8 IND. Rr Display Rear–E
9 N.C Not used
10 N.C Not used
11 SOL (+) EMC
12 Ref Speed Reference
13 COM (–) Speed Return
14 VIG Ignition
15 TPS TPS (PWM)
16 TECH 2 TECH–2
17 IND. a Display Front–A
18 IND. c Display Front–C
19 IND. AUTO Display Auto–D
20 CHECK Check T/F
21 N.C Not used
22 P–GND Power Ground
23 ADC (+) Axle Disconnect Output
24 N.C Not used
25 N.C Not used
No. NAME CONTENTS

26 N.C Not used
27 N.C Not used
28 N.C Not used
29 DIAG Diagnostic Input
30 TOD SW TOD Switch
31 4H SW 4H Switch Input
32 Frt. Sig Front Speed Signal
33 ABS IN ABS In
34 VIG Ignition
35 N.C Not used
36 4WD OUT 4WD Signal Output
37 BRAKE Brake Switch Input
38 N.C Not used
39 N.C Not used
40 LIGHTING SW Lighting Switch Input
41 N.C Not used
42 AXLE SW Axle Switch Input
43 N.C Not used
44 4L SW 4L Switch Input
45 Rr. Sig Rear Speed Signal
46 GND ECU Ground 1
47 GND. 2 ECU Ground 2
48 N.C Not used
Reference
D Transfer connector pin assignment (connector on the
transfer case)
for inspection of transfer pins.
810RW310
No. NAME CONTENTS

1 Ref. (Rer. ) Rear speed sensor reference output
2 Ref. (Frt. ) Front speed sensor reference output
3 SW GND SW GND
4 4H SW (+) 4H SW plus terminal
5 Rer. (+) Rear speed sensor plus
6 Frt. (+) Front speed sensor plus
7 POWER GND Power GND
8 SOL (+) Electromagnetic solenoid
9 COM (–) (Rer. ) Rear speed sensor GND
10 COM (–) (Frt. ) Front speed sensor GND
11 NC Not used
12 4L SW (+) 4L SW plus terminal
Checking Failed TOD Control Unit Pin

NOTE: 2. Before removing the ECU, turn off the ignition switch.
1. Unplug the ECU connector and the pins, unless 3. If the standard values are not observed, check the
otherwise specified. pins with other testers.
Che Circuit to be Ignition Engine Multime- Measure be- Standard Valve Note
ck tested Switch State ter tween Pin
Pin Position Scale/ Number
No. Range
4 D-G MAP OFF STOP W 4, 46 Continuity : OK
22 P-GND OFF STOP W 22, 46 Continuity : OK
46 GND OFF STOP W 46, GND Continuity : OK
31 4H SW OFF STOP W 31, 46 No continuity (high,
4L) and continuity
(N) : OK
44 4L SW OFF STOP W 44, 46 No continuity (high)
and continuity (4L,
N) : OK
42 AXLE SW ON RUN W 42, 46 Continuity : OK Remove ECU and start the engine. Move
the vehicle forth and back to connect axle
surely.
29 DIAG OFF STOP W 29 (TOD), 8 Continuity : OK DLC connector terminal 8
(DLC Con-
nector)
17 IND.a ON STOP DCV 17 (+), 46 (–) 8.0 ∼14.5 V
6 IND.b ON STOP DCV 6 (+), 46 (–) 8.0 ∼14.5 V
18 IND.c ON STOP DCV 18 (+), 46 (–) 8.0 ∼14.5 V
20 CHECK ON STOP DCV 20 (+), 46 (–) 8.0 ∼14.5 V
LAMP
33 ABS IN ON STOP DCV 33 (+), 46 (–) 11.5 ∼14.5 V
12 Ref. ON STOP DCV 12 (+), 46 (–) 5 ∼9 V Connect ECU
32 Ft.(+) ON STOP DCV 32 (+), 46 (–) 0.7 ∼6 V Connect ECU and move the vehicle (off one
tooth of speed sensor ring) making sure of
voltage change.
45 Rr.(+) ON STOP DCV 45 (+), 46 (–) 0.7 ∼6 V Connect ECU and move the vehicle (off one
tooth of speed sensor ring) making sure of
voltage change.
13 COM(-) ON STOP DCV 13 (+), 46 (–) 0V Connect ECU
14 Vig ON STOP DCV 14 (+), 46 (–) 8 ∼14.5 V
37 BRAKE OFF STOP DCV 37 (+), 46 (–) 8 ∼14.5 V Press brake pedal
15 TPS ON STOP DCV 15 (+), 46 (–) PWM duty cycle Step on the accelerator pedal and make
10% – 90% sure that duty cycle changes.
36 4WD OUT OFF STOP W 36, 46 7 ∼12 kW Disconnect battery GND terminal
23 ADC(+) OFF STOP W 23, 46 10 ∼30 W Disconnect battery GND terminal
11 SOL(+) OFF STOP W 11, 46 1.0 ∼5.0 W Disconnect battery GND terminal
30 TOD SW ON STOP DCV 30 (+), 46 (–) SW OFF : 8.0 ∼14.5 SW OFF : Contact point open
V SW ON : Contact point close
SW ON : 0 V
40 LIGHTING ON STOP DCV 40 (+), 46 (–) SW OFF : 8.0 ∼14.5
V
SW ON : 0 V
19 AUTO INDI ON STOP DCV 19 (+), 46 (–) TOD : 0 V
2H : 8.0 ∼14.5 V
8 RR INDI ON STOP DCV 8 (+), 46 (–) 0V
34 VIG ON STOP DCV 34 (+), 46 (–) 8 ∼14.5 V
Tech 2 Scan Tool
From 98 MY, Isuzu dealer service departments are
recommended to use Tech 2. Please refer to Tech 2 scan
tool user guide.
901RW257
Legend (3) DLC Cable

(1) PCMCIA Card (4) Tech 2
(2) SAE 16/19 Adaptor
Getting Started Operating Procedure

D Before operating the Isuzu PCMCIA card with the The power up screen is displayed when you power up the
Tech 2, the following steps must be performed: tester with the Isuzu systems PCMCIA card. Follow the
1. The Isuzu 98 System PCMCIA card (1) inserts into operating procedure below.
the Tech 2 (4).
2. Connect the SAE 16/19 adapter (2) to the DLC cable
(4).
3. Connect the DLC cable to the Tech 2 (4)
4. Mark sure the vehicle ignition is off.
5. Connect the Tech 2 SAE 16/19 adapter to the vehicle
DLC connector.
821RW021
6. The vehicle ignition turns on.

7. Power up the Tech 2.
8. Verify the Tech 2 power up display.
060RY027
060RW009
060RX062
Diagnostic Trouble Codes

Code Item Diagnosis Check flow No.
12 Start code Normal —
13 Ref Shorted GND 6
14 Front speed sensor Input abnormality (open, sig or com) 2
15 Ref Shorted VB 6
16 Front speed sensor Input abnormality 3
21 TPS Shorted or disconnected wiring, abnormality in 7
input
23 ECU CPU abnormality 1
24 Rear speed sensor Input abnormality (open, sig or com) 5
26 EMC (+) Shorted GND 10
27 Rear speed sensor Input abnormality 4
28 ADC (+) & AXLE SW Output abnormality 11
31 EMC (+) Shorted or disconnected coil/wiring 9
32 ADC (+) Shorted or disconnected coil/wiring 12
33 ADC (+) Shorted GND 13
TPS : Throttle Position Sensor

EMC : Electromagnetic coil
ADC : Shift on the fly (Axle Dis Connect)
Diagnosis from Trouble Codes

D Diagnose the based on the fault that have been saved
to the control unit according to the system
self-diagnostic function.
Check flow Trouble code Phenomenon Standard

1 23, 36, 37, 38 The ECU is failed. —
Step Action Yes No

1 Turn on the starter switch. Replace the ECU
and conduct the
Is the trouble reproduced?
test run.
Go to Step 3 Go to Step 2
2 1. Clear the trouble codes. The trouble is not
2. Conduct the test run. reproduced.
Refer to
Is the trouble reproduced during the test run?
Replace the ECU “Troubles
and conduct the intermittently
test run. observed”.
3 1. Check that all the parts are mounted.
2. Clear the trouble codes.
Repeat the
Is this step complete? “Diagnosis Flow”. Return to Step 3

2 14 Front speed sensor signal open or 0.3 < sensor voltage
GND short, speed sensor com
open.
NOTE: The following procedure shows the case that the

front or rear sensor common grounding line is broken.
D04RY00004
Step Action Yes No

1 1. Start the engine.
2. Select 4H (TOD) mode.
Is the memory except DTC 14? Go to Step 3 Go to Step 2
2 Is the continuity between harness of terminal 32 and ground Replace speed
(vehicle side terminal of the front speed sensor)? sensor. Repair the circuit.
3 Is the memory DTC 24? Refer to other
trouble check
flow.
4 Is the continuity between harness of terminal 32 and 45 (vehicle Repair the circuit.
side terminal of the front and rear speed sensor)? Go to Step 5 Go to Step 6
5 Is the continuity between harness of terminal 12 and 13 (vehicle Replace front and
side terminal of the speed sensor COM and ref)? rear speed
sensor. Repair the circuit.
6 1. Check that all the parts are mounted. The trouble is not
2. Clear the trouble code. reproduced.
Refer to
Is the step complete?
“Troubles
intermittently
Repeat the observed”.
“Diagnosis Flow”. Return to Step 6

3 16 The front speed sensor no pulse. Hi level : 4.5 ∼ 6.0 V
Lo level : 0.7 ∼ 2.0 V
Frequency (F) =
766 Hz (at 30 mile/h)
NOTE: Find the trouble in which the pulse corresponding

to the running speed is not input.
D04RY00004
Step Action Yes No

1 1. Connect TECH 2. Repair and
inspection front
While running in TOD mode, does TECH–2’s front speed sensor
speed sensor
indication change with vehicle speed?
tone wheel.
(vehicle side terminal of the front speed sensor)? sensor. Repair the circuit.
3 1. Clear the trouble code.
While running at 30 mph in TOD mode for 30 consecutive sec, is Replace ECU.
trouble code reissued? Go to Step 4 Go to Step 4
Refer to
Is this step complete?
“Troubles
intermittently

4 27 The front speed sensor no pulse. Hi level : 4.5 ∼ 6.0 V
Lo level : 0.7 ∼ 2.0 V
Frequency (F) =
766 Hz (at 30 mile/h)
NOTE: Find the trouble in which the pulse corresponding

to the running speed is not input.
D04RY00004
Step Action Yes No

1 1. Connect TECH 2. Repair and
inspection front
While running in TOD mode, does TECH–2’s front speed sensor
speed sensor
indication change with vehicle speed?
tone wheel.
(vehicle side terminal of the rear speed sensor)? sensor. Repair the circuit.
3 1. Clear the trouble code.
While running at 30 mph in TOD mode for 30 consecutive sec, is Replace EUC.
trouble code reissued? Go to Step 4 Go to Step 4
Refer to
Is this step complete?
“Troubles
intermittently

5 24 Rear speed sensor signal open or 0.3 V < sensor voltage
GND short, speed sensor COM
open.
NOTE: The following procedure shows the case that the

front or rear sensor common grounding line is broken.
D04RY00004
Step Action Yes No

2. Select 4H (TOD) mode.
Is the memory except DTC 24? Go to Step 3 Go to Step 2
(vehicle side terminal of the rear speed sensor)? sensor. Repair the circuit.
3 Is the memory DTC 14? Refer to other
trouble cheek
flow.
4 Is the continuity between harness of terminal 32 and 45 (vehicle Repair the circuit
side terminal of the front and rear speed sensor)? Go to Step 5 Go to Step 6
5 Is the continuity between harness of terminal 12 and 13 (vehicle Replace front and
side terminal of the speed sensor COM and ref)? rear speed
sensor. Repair the circuit.
Refer to
Is the step complete?
“Troubles
intermittently

6 13 The reference is short-circuited to Reference ] 5 V
GND.
15 The reference Vb is short-circuited.
If the reference wire (15) is short-circuited to GND, the

speed signal is not generated. If the wire is short-circuited
to the battery voltage, the signal level becomes faulty.
D04RY00004
Step Action Yes No

Does the voltage between terminals 12 and 13 meet the standard
5V? Go to Step 8 Go to Step 2
2 Is the voltage below the standard? Go to Step 3 Go to Step 7
3 1. Turn off the starter switch. The ECU is
2. Disconnect the ECU connector. failed. Replace
Is the continuity established between vehicle harness terminals the ECU.
(B–49)12 and (B–48)24? Go to Step 4 Go to Step 8
4 1. Disconnect the H-17 connector.
Is the continuity established between floor harness connector
terminals (H-17)1 and (H-17)8? Go to Step 5 Go to Step 6
5 1. Disconnect the M-27 connector. The reference
harness for the
Is the continuity established between transfer harness connector
front speed
terminals (M–27)2 and (M–27)7?
sensor is
short–circuited to
Replace the front GND. Repair the
speed sensor. circuit.
6 1. Disconnect the M-27 connector. The reference
harness for the
Is the continuity established between transfer harness connector
front speed
sensor is
short–circuited to
Replace the rear GND. Repair the
speed sensor. circuit.
7 1. Turn off the starter switch.
2. Disconnect the ECU connector. The ECU has
3. Turn on the starter switch. Repair the failed. Replace
Is the battery voltage observed between harness connector harness circuit. the ECU.
terminals (B–49)12 and (B–48)24? Go to Step 8 Go to Step 8
2. Clear the trouble code.
Repeat the
Is this step complete? “Diagnosis Flow” Go to Step 8

7 21 The voltage of the throttle position See below table.
sensor (TPS) is faulty.
NOTE: The signal voltage from the TPS deviates from

the standard range.
D04RY00004
D04RY00012
Step Action Yes No

1 1. Turn off the starter switch. Charge or
replace the
Is the battery voltage normal?
battery.
2 1. Turn on the starter switch.
Does the voltage between terminals 15 and 46 fall within the
standard range above? Go to Step 6 Go to Step 3
2. Disconnect the ECU connector. The ECU has
3. Turn on the starter switch. failed. Replace
Does the voltage between terminals (B–49)15 and (B–48)24 fall the ECU.
within the standard range above? Go to Step 6 Go to Step 4
4 Is the harness healthy? Repair the
harness.
5 Is the TPS healthy? Replace the TPS.
Repeat the
Is this step complete? “Diagnosis Flow”. Go to Step 6

9 31 The electromagnetic coil is broken. —
D04RY00008
Step Action Yes No

2. Disconnect the ECU connector from ECU.
Is the continuity established between terminals (B–49)11 and
(B–49)22? Go to Step 2 Go to Step 4
2 1. Connect the ECU connector.
2. Start the engine. The ECU has
3. Set the TOD mode. failed. Replace
Does the voltage between terminals 11 and 22 indicate at least the ECU.
0.4V? Go to Step 3 Go to Step 5
3 Is the battery voltage always observed between terminals 11 and The phenomenon
22? is not
reproduced.
The harness is Refer to
short–circuited on “Troubles
the battery. intermittently
Repair the circuit. observed”.
4 1. Disconnect the M–27 connector. Replace the
transfer
Is the continuity established between transfer connector
The harness is electromagnetic
broken. Repair coil (solenoid
the circuit. clutch).
Repeat the

10 26 The electromagnetic coil GND is Resistance: 1.0 to 5.0 ohm (at ordi-
short-circuited. nary temperature)
D04RY00008
Step Action Yes No

2. Disconnect the ECU connector from ECU.
Does the resistance between terminals (B–49)11 and (B–49)22
indicate 1.0 to 5.0 ohm? Go to Step 2 Go to Step 3
2 1. Connect the ECU connector. The phenomenon
2. Start the engine. is not
3. Set the TOD mode. reproduced.
Refer to
When the throttle is operated between full close and full open
“Troubles The ECU has
positions, does the voltage between terminals 11 and 22 indicate
intermittently failed. Replace
at least 0.1 to 1.0 V?
observed”. the ECU.
3 Does the resistance between transfer connector terminals Replace the
(M–27)8 and (M–27)7 indicate 1.0 to 5.0ohm? The harness is transfer
broken. Repair electromagnetic
the circuit. coil.
Repeat the

11 28 The shift on the fly system (front —
hub) works incorrectly.
NOTE: The shift on the fly system is not changed

between 2WD and 4WD modes normally.
CAUTION: If code 32 or 33 is also observed, remove
the trouble associated with code 32 or 33 first.
D04RY00008
Step Action Yes No

2. Set the transfer to the 2H mode.
Is the battery voltage observed between terminals 23 and 46? Go to Step 2 Go to Step 5
2 Is the battery voltage observed between terminals 42 and 46? Go to Step 3 Go to Step 6
3 1. Set the transfer to the high (TOD) mode. The ECU has
failed. Replace
Does the voltage between terminals 23 and 46 indicate 0V?
the ECU.
4 Does the voltage between terminals 42 and 46 indicate 0V? The phenomenon
is not
reproduced. The shift on the
Refer to fly system is
“Troubles failed (refer to
intermittently Section 4C “Front
observed”. Axle”).
5 Does the TOD indicator show the 2H mode? See “Trouble
Diagnosis
The ECU has Depending on
failed. Replace The Status of
the ECU. TOD Indicator”.
6 Set the transfer to the high (TOD) mode. The shift on the
fly system has
Does the voltage between terminals 23 and 46 indicate 0V?
failed (refer to
Section 4B1 The ECU has
“Driveline Control failed. Replace
System”). the ECU.
Repeat the

12 32 The on/off signal (ADC) line of the —
shift on the fly system (front hub) is
broken, or the line is short-circuited
to the battery.
NOTE: The on/off signal line of the shift on the fly system
is broken, or the line is short–circuited to the battery.
D04RY00008
Step Action Yes No

1 1. Turn off the starter switch. The harness is
2. Disconnect the ECU connector from ECU. broken. Repair
Is the continuity established between terminals (B–48)1 and the circuit.
2 Does the voltage between terminals (B–48)1 and (B–48)24 The battery is
indicate 0V? short-circuited.
Repair the circuit.
3 1. Turn off the starter switch. The phenomenon
2. Connect ECU connector. is not reproduced
3. Turn on the starter switch. Refer to
4. Set the transfer to the 2H mode. “Troubles The ECU has
Is the battery voltage observed between terminals 23 and 46?
Repeat the

13 33 The ADC line is short-circuited to —
GND.
NOTE:
D The on/off signal line of the shift on the fly system is
short–circuited to GND.
D The system enters into the fail-safe mode because of
fusing or system protection.
(If a short–circuit is observed on GND, the output to
the on/off signal line becomes 0V.)
D04RY00008
Step Action Yes No

1 1. Turn off the starter switch. The phenomenon
2. Disconnect the ECU connector from ECU. is not
reproduced.
Does the resistance between terminals (B–48)1 and (B–48)24
Refer to
meet the standard, R = 21 ± 4 ohms?
“Troubles
intermittently
observed”.
2 Is the resistance between terminals (B–48)1 and (B–48)24 R<2 The signal line
ohms? circuit of the shift
on the fly system
is short-circuited
to GND. Repair
the circuit.
3 Is the resistance between terminals (B–48)1 and (B–48)24 R= The signal line
9±7ohms? circuit of the shift
on the fly system
is layer
short-circuited*.
Replace the valve
(VSV).
Repeat the
*Layer short-circuit : The coil is damaged by overcurrent.
Trouble Diagnosis Depending on The

Status of TOD Indicator
Functional check with TOD indicator light is conducted
prior to check on Charts A–H.
D After the starter is switched on, check and see if the
status has become as tabulated below.
C07RY00019
D If the status is as tabulated above, there is no

problem. If not as tabulated above, inspect the
harness.
Chart A Indicator drive circuit

Function of circuit The circuit informs the indicator of the working condition of the ECU.
Fail condition All the TOD indicator lamps and CHECK lamp are lit, and go off momentarily at an inter-
val of about two seconds.
Indicator lamp status —
Transfer position 2H, TOD, 4L —
D04RY00015
Step Action Yes No

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

1 1. Turn on the starter switch. Repair the 4WD
Auto Switch
When the 4WD Auto Switch is select to the 4WD position, is 0 V
circuit.
observed between terminal 30 and 46?
2 When the 4WD Auto Switch is select to the 2WD position, is 12 V Repair the 4WD
observed between terminals 30 and 46? Auto Switch
circuit.
3 When the transfer lever is shifted to the 4L position, is battery The phenomenon
boltage observed between terminals 19 and 46? is not
reproduced.
Refer to
“Troubles
intermittently Replace the
observed”. ECU.
Repeat the
Chart B–2 The 4WD AUTO SWITCH circuit is short to battery.

Fail condition Even after the transfer mode is select from 2H to TOD.
Indicator lamp status
Transfer position TOD
D04RY00015
Step Action Yes No

observed between terminal 30 and 46 (4H switch)? Auto Switch
circuit.
observed between terminals 30 and 46 (4H switch)? Auto Switch
circuit.
3 1. Disconnect the ECU connector. Replace TOD
indicator lamp
bulb.
(B–49)17?
4 Is the continuity established between terminals (B–49)14 and Replace TOD
(B–49)6? indicator lamp
bulb.
bulb.
Replace ECU. bulb.
Repeat the
Chart C–1 4H switch circuit wires are broken or the battery is short-circuited.
Fail condition When the 4WD Auto Switch is 4WD mode.
When the lever is shifted from 4L to TOD, the 4L mode remains on the indicator and the
TOD mode is displayed without turning off the previous mode.
Transfer position 4L <——> Neutral <——> TOD
D04RY00015
Step Action Yes No

When the transfer lever is shifted to the high position, is 5V
observed between terminals 31 and 46 (4H switch)? Go to Step 2 Go to Step 4
2 When the transfer lever is shifted to the 4L position, is 5V
3 When the transfer lever is shifted to the neutral position, is 0V Replace the
observed between terminals 31 and 46 (4H switch)? ECU.
2. Disconnect the ECU connector.
3. Turn on the starter switch.
observed between terminals (B–48)9 and (B–48)24 (4H switch)? Go to Step 5 Go to Step 7
5 When the transfer lever is shifted to the neutral position, is 0V
observed between terminals (B–48)9 and (B–48)24 (4H switch)? Go to Step 6 Go to Step 7
6 When the transfer lever is shifted to the 4L position, is 12V The 4H switch
observed between terminals (B–48)9 and (B–48)24 (4H switch)? circuit battery is
short-circuited
between ECU
and transfer.
Repair the circuit.
7 Turn off the starter switch.
When the transfer lever is shifted to the neutral position, is the
continuity established between terminals (B–48)9 and (B–48)24
(4H switch)? Go to Step 8 Go to Step 10
8 When the transfer lever is shifted to the high position, is the
continuity established between terminals (B–48)9 and (B–48)24? Go to Step 10 Go to Step 9
9 When the transfer lever is shifted to the 4L position, is the The phenomenon
continuity established between terminals (B–48)9 and (B–48)24? is not
reproduced.
Refer to
“Troubles
intermittently
observed”.
10 When the transfer lever is shifted to the neutral position, is the Repair the
continuity established between terminals (M–27)4 and (M–27)7? transfer
assembly.
11 When the transfer lever is shifted to the high position, is the Repair the
continuity established between transfer connector terminals transfer
(M–27)4 and (M–27)7? assembly.
12 When the transfer lever is shifted to the 4L position, is the Repair the
(B–48)9 and (M–27)4? assembly.
Step Action Yes No

13 Is the continuity established between transfer terminals (M–27)4 The harness is
and body? broken between
The ECU has terminal (M-27)4
failed. Replace and GND. Repair
the ECU. the circuit.
Repeat the
Chart C–2 The 4H switch circuit is short-circuited to GND.

Fail condition When the transfer lever is shifted to 4L, the indicator lamp status is not changed.
Transfer position 4L
D04RY00015
Step Action Yes No

1 When the transfer lever is shifted to the High position, is 5V
4 1. Turn off the starter switch. Replace TOD
indcator lamp
Is the continuity established between terminals 14 and 17?
bulb.
5 Is the continuity established between terminals 14 and 6? Replace TOD
indicator lamp
bulb.
indicator lamp
bulb.
indicator lamp
bulb.
indicator lamp
bulb.
9 1. Turn on the starter switch. The ECU has
2. Shift the transfer lever is shifted to the 4L position. failed. Replace
the ECU.
Is 0 V observed between terminals 17 and 22?
10 Is 0 V observed between terminals 6 and 22? The ECU has
failed. Replace
the ECU.
failed. Replace
the ECU.
failed. Replace
the ECU.
13 Is 0 V observed between terminals 8 and 22? The phenomenon
is not
reproduced.
Refer to
Step Action Yes No

When the transfer lever is shifted to the neutral position, is the
(4H switch)? Go to Step 15 Go to Step 17
continuity established between terminals (B–48)9 and (B–48)24? Go to Step 17 Go to Step 16
16 When the transfer lever is shifted to the 4L position, is the The ECU has
continuity established between terminals (B–48)9 and (B–48)24? failed. Replace
the ECU.
17 1. Disconnect the H–17 connector.
When the transfer lever is shifted to the neutral position between
high and 4L, is the continuity established between terminals
(H-17)3 and (B-48)9? Go to Step 18 Go to Step 20
continuity established between transfer connector terminals
19 When the transfer lever is shifted to the 4L position, is the GND is
continuity established between transfer connector terminals short-circuited
(H-17)3 and (B-48)9? between
terminals (B-48)9
and (H-17)3.
Repair the circuit.
20 1. Disconnect the M–27 connector. Repair the
When the transfer lever is shifted to the neutral position between transfer
high and 4L, is the continuity established between terminals assembly.
(M-27)4 and (B-48)9? Go to Step 21 Go to Step 23
continuity established between terminals (M-27)4 and (B-48)9? transfer
assembly.
22 When the transfer lever is shifted to the 4L position, is the GND is
continuity established between terminals (M-27)4 and (B-48)9? short-circuited
between
Repair the terminals (B-48)9
transfer and (M–27)4.
assembly. Repair the circuit.
Repeat the
Chart D–1 4L switch circuit wires are broken or the battery is short-circuited.
Fail condition The TOD mode is displayed in the neutral position between high and 4L. When the lever
is shifted to the 4L position, the TOD mode is displayed.
Transfer position 4L Neutral
D04RY00004
Step Action Yes No

1 Turn on the starter switch.
observed between terminals 44 and 46 (4L switch)? Go to Step 2 Go to Step 4
3 When the transfer lever is shifted to the 4L position, is 0V The ECU has
observed between terminals 44 and 46 (4L switch)? failed. Replace
the ECU.
3. Turn on the starter switch.
observed between terminals (B–48)22 and (B–48)24 (4L switch)? Go to Step 5 Go to Step 7
observed between terminals (B–48)22 and (B–48)24 (4L switch)? Go to Step 6 Go to Step 7
6 When the transfer lever is shifted to the 4L position, is 0V The 4L switch
observed between terminals (B–48)22 and (B–48)24 (4L switch)? circuit battery is
short-circuited
between ECU
and transfer.
Repair the circuit
7 Turn off the starter switch.
When the transfer lever is shifted to the high position, is the
(4L switch)? Go to Step 10 Go to Step 8
8 When the transfer lever is shifted to the neutral position between
(B–48)22 and (B–48)24 (4L switch)? Go to Step 9 Go to Step 10
9 When the transfer lever is shifted to the 4L position, is the The phenomenon
continuity established between terminals (B–48)22 and (B–48)24 is not
(4L switch)? reproduced.
Refer to
“Troubles
intermittently
observed”.
10 1. Disconnect the M–27 connector. Wires are broken
between transfer
connector (M-27)
high and 4L, is the continuity established between transfer
and floor Repair the
connector terminals (M-27)12 and GND?
connector (H-17). transfer
Repair the circuit. assembly.
(M-27)12 and GND? assembly.
Step Action Yes No

(M-27)12 and GND? assembly.
Repeat the
Chart D–2 The 4L switch circuit is short-circuited to GND.

Fail condition The 4L mode is displayed even in the 2H or TOD.
Transfer position 2H or TOD
D04RY00006
Step Action Yes No

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

continuity established between terminals (M-27)12 and GND? transfer
assembly.
15 When the transfer lever is shifted to the high position, is the GND is
continuity established between terminals (M-27)12 and GND? short-circuited
between
Repair the terminals (H–17)6
transfer and (M-27)12.
assembly. Repair the circuit.
Repeat the
Chart E–1 AXLE switch circuit wires are broken.

Fail condition Both the TOD and 4L modes are disabled. (The transition status is not removed.)
Transfer position TOD 4L
D04RY00007
Step Action Yes No

1 Start the engine.
high and 4L, is the battery voltage observed between terminals 42
and 46? Go to Step 2 Go to Step 7
2 When the transfer lever is shifted to the high position and 4WD
Auto switch selected to 4WD position, is 0V observed between
terminals 42 and 46? Go to Step 3 Go to Step 7
observed between terminals 42 and 46? Go to Step 4 Go to Step 7
4 Shift the transfer lever to the 4L position. The ECU has
failed. Replace
Is 0V observed between terminals 17 and 46?
the ECU.
5 Is 0V observed between terminals 6 and 46? The ECU has
failed. Replace
the ECU.
is not
reproduced.
Refer to
Auto Switch selected to the 2WD position, is the battery voltage
9 When the transfer lever is shifted to the high position (TOD mode),
is 0V observed between terminals 23 and 46? Go to Step 10 Go to Step 11
11 Is any of the trouble codes 28, 32 and 33 recorded? Examine the
trouble based on The ECU has
“Diagnosis from failed. Replace
Trouble Codes”. the ECU.
12 1. Turn off the starter switch. Repair the circuit
2. Disconnect the ECU connector. of replace the
Does the resistance between terminals (B–48)1 and (B–48)24 VSV.
meet the standard, 17< R < 25 ohm? Go to Step 13 Go to Step 19
13 1. Turn on the starter switch. Repair the circuit
of replace the
When the 4WD Auto Switch is select to the 2WD position, is the
VSV.
battery voltage supplied to each VSV?
14 When the transfer lever is shifted to the neutral position between Repair the circuit
high and 4L, is the battery voltage supplied to each VSV? of replace the
VSV.
Step Action Yes No

15 When the transfer lever is shifted to the high position and 4WD Repair the circuit
Auto Switch selected to 4WD position, is 0V observed on each of replace the
VSV? VSV.
16 When the transfer lever is shifted to the 4L position, is 0V Repair the circuit
observed on each VSV? of replace the
VSV.
17 Is the vacuum pressure supplied to the VSV? Repair the
vacuum system.
18 Can the single AXLE switch enable and disable the continuity? Repair the shift Replace the
on the fly system AXLE switch
(refer to Section (refer to Section
4B1 “Driveline 4B1 “Driveline
Control System”). Control System”).
Repeat the
Chart E–2 The AXLE switch circuit is short-circuited to GND.

Fail condition Even after the 4WD Auto Switch is select to the 2WD position, the 2WD mode is not en-
abled. (The transition status is not removed.)
Transfer position 2H
D04RY00007
Step Action Yes No

1 Start the engine.
Auto Switch selected to 4WD position, is 0V observed between
4 Select the 4WD Auto Switch to the 2WD position.
Is 12V observed between terminals 17 and 46? Go to Step 5 Go to Step 19
5 Is 12V observed between terminals 6 and 46? Go to Step 6 Go to Step 19
is not
reproduced.
Refer to
7 When the 4WD Auto Switch is select to the 2WD position, is the
battery voltage observed between terminals 23 and 46? Go to Step 8 Go to Step 11
Auto Switch selected to 4WD position, is 0V observed between
trouble based on The ECU has
“Diagnosis from failed. Replace
Trouble Codes”. the ECU.
2. Disconnect the ECU connector. of replace the
Does the resistance between terminals (B–48)1 and (B–48)24 VSV.
meet the standard, 17< R < 25 ohm? Go to Step 13 Go to Step 19
13 1. Connect the ECU connector. Repair the circuit
2. Turn on the starter switch. of replace the
When the 4WD Auto Switch is select to the 2WD position, is the VSV.
battery voltage supplied to each VSV? Go to Step 14 Go to Step 19
14 When the transfer lever is shifted to the neutral position between Repair the circuit
high and 4L, is the battery voltage supplied to each VSV? of replace the
VSV.
15 When the transfer lever is shifted to the high position and 4WD Repair the circuit
Auto Switch selected to 4WD position, is 0V observed on each of replace the
VSV? VSV.
Step Action Yes No

16 When the transfer lever is shifted to the 4L position, is 0V Repair the circuit
observed on each VSV? of replace the
VSV.
17 Is the vacuum pressure supplied to the VSV? Repair the
vacuum system.
18 Can the single AXLE switch enable and disable the continuity? Repair the shift Replace the
on the fly system AXLE switch
(refer to Section (refer to Section
4B1 “Driveline 4B1 “Driveline
Control System”). Control System”).
Repeat the
Chart G The trouble codes are displayed.

Fail condition
Transfer position —
D04RY00009
Step Action Yes No

1 Disconnect the ECU connector from ECU. The ECU has
failed. Replace
the ECU.
(B–48)24?
2 Is the self-diagnostic connector short-circuited? Open the
self-diagnostic
connector.
2. Clear the trouble codes.
Repeat the
Is this step complete? “Diagnosis Flow”. Repeat to Step 3
Chart H lighting switch circuit

Function of circuit Reads in the status of lighting switch, reducing the indicator at night.
Fail condition Even if the lighting switch is pressed on and off, brightness does not change.
Transfer position All position (exsample TOD mode)
D04RY00009
Step Action Yes No

1 1. Disconnect ECU terminal. Wires are broken
2. Turn on the starter switch. lighting SW
circuit. Repair
Is battery voltage observed between ECU terminals (B–48)18
the circuit.
and (B–48)24?
2 Turn lighting SW “ON”. Lighting SW
circuit battery
Is 0 V observed between ECU terminal (B–48)18 and (B–48)24?
short. Repair the
circuit.
3 Connect ECU terminal. The phenomenon
is not
While the lighting switch is pressed on and off, does the
reproduced.
brightness of the indicator change?
Refer to
observed” the ECU.
Repeat the
Diagnosis from Symptom

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

Fail condition When the vehicle is subject to full steering in the TOD mode, the drive resistance gets
large or the judder occurs. Otherwise, the above phenomenon is observed only when the
brake is applied.
D04RY00009
Step Action Yes No

1 Are the front and rear tires in specified size? Replace the tires
with specified
ones, and service
the new tires.
2 Is the tire pressure correct? Replace the tires
with specified
ones, and service
the new tires.
3 Are the tires free from abnormal wear? Replace the tires
with specified
ones, and service
the new tires.
4 Are different types of tires used? Replace the tires
with specified
ones, and service
the new tires.
2. Shift the transfer lever to the high (TOD) position.
3. Fully turn the steering to the left (or right) end, and select the D
range and start the creep run.
Does the tight corner braking occur? Is the judder with chug-chug
sound observed? * Use caution on the operation. Go to Step 6 Go to Step 11
6 1. Shift the transfer lever to the 2H position.
Does the tight corner braking occur? Is the judder with chug-chug
sound observed? * Use caution on the operation. Go to Step 7 Go to Step 14
7 Is an LSD mounted to the rear differential? Go to Step 8 Go to Step 9
8 Is the genuine LSD oil used in the rear differential? Replace the
differential oil.
9 Does the engine output the power correctly? Check the
engine.
10 Do the speed sensors work correctly? (Check trouble codes.) The ECU has
failed. Replace Replace the
the ECU. speed sensors.
11 Is the tight corner braking observed only when the brake is Conduct full
applied? steering under
WOT.
2. Disconnect the ECU connector. of terminal 6
Is the battery voltage observed between terminals (B–48)11 and (ABS IN).
Step Action Yes No

13 1. Apply the brake and fully turn the steering to the left (or right) Repair the The ECU has
end, and start the creep run. transfer failed. Replace
Does the voltage between terminals (B–49)11 and (B–49)22 assembly. the ECU.
range between 0.1 and 1.0V? Go to Step 16 Go to Step 16
14 1. Shift the transfer lever to the high (TOD) position.
Does the voltage between terminals 11 and 22 range between 0.1
and 1.0V? Go to Step 15 Go to Step 13
15 1. Select the 4WD Auto Switch to the 2WD position. The phenomenon
2. Jack up the right front wheel. is not
reproduced.
Does the front tire rotate smoothly?
Refer to
Repair the “Troubles
transfer intermittently
assembly. observed”.
Repeat the
*NOTE: Before checking this item, run the vehicle more
than 10 meters with the steering wheel in straight position
so that the 4L mechanical lock sleeve can be released
certainly.
Chart 2 The 4WD mode is not active.

Fail condition The rear wheels spin in the TOD mode, so the driving torque is not transmitted to the
front wheels. The indicator lamps will not show the 4L and TOD status.
D04RY00009
Step Action Yes No

1 Is the trouble code 31 or 26 recorded? Examine the
trouble based on
“Diagnosis from
Trouble Codes”.
trouble based on
“Diagnosis from
Trouble Codes”.
3 When the transfer lever is in the specified position, do the TOD Examine the
indicator lamps show the correct status? trouble based on
“Trouble
Diagnosis
Depending on
The Status of
TOD Indicator”.
4 Shift the transfer lever to the 4L position, fully turn the steering to Repair the
the left (or right) end, and start the creep run. Does the tight transfer
corner braking occur? assembly.
5 1. Shift the transfer lever to the high (TOD) position. The ECU has
2. Turn on the starter switch. failed. Replace
Does the voltage between terminals 11 and 22 indicate at least the ECU.
0.1V while the throttle is completely open? Go to Step 6 Go to Step 7
6 Does the voltage between terminals 11 and 22 indicate at least 3V The TOD clutch
while the throttle is completely closed? is worn. Repair The ECU has
the transfer failed. Replace
assembly. the ECU.
Repeat the
Chart 3 The shift on the fly system generates gear noises.

(The fuel economy is bad in the 2H mode.)
Fail condition When the vehicle is run in the 2H mode, the shift on the fly system generates gear
noises or the front wheel gears are engaged to generate a shock.
D04RY00015
Step Action Yes No

1 Do the indicator lamps show the correct status? Examine the
trouble based on
“Diagnosis from
Trouble Codes”.
trouble based on
“Diagnosis from
Trouble Codes”.
3 Turn on the starter switch.
Is the battery voltage observed between terminals 14 and 22? Go to Step 4 Go to Step 5
4 When the 4WD Auto Switch is select to the 2WD position, are the The phenomenon
front axle gears correctly disengaged (and when the left front tire is not The shift on the
is jacked up and turned, is the front propeller shaft standstill)? reproduced. fly system is
Refer to failed (refer to
“Troubles Section 4B1
intermittently “Driveline Control
observed”. System”).
5 Does the battery voltage maintain the correct level? Repair the battery
Repair the battery and charging
circuit. system.
Repeat the
Chart 4 The braking distance gets long even when the ABS is active.
Fail condition Enough deceleration is not obtained and the braking distance gets long even when the
ABS is active in the 2H mode.
D04RY00009
Step Action Yes No

1 Are the brake and ABS systems healthy? Repair the
brake and ABS.
2 Turn on the starter switch. Repair the
Is the battery voltage observed between terminals 14 and 22? battery system.
3 1. Select the 4WD SW to the 2WD position.
2. The voltage between terminals 36 and 46 range between 7.5
and 16V (0.12 seconds make a cycle)
Examine the
trouble based
on “Diagnosis The ECU has
from Trouble failed. Replace
Codes". the ECU.
Does the voltage within the range specified? Go to Step 4 Go to Step 4
4 Check that all the parts are mounted. Repeat the
Is this step complete? “Diagnosis Flow". Return to Step 4
DRIVE SHAFT SYSTEM 4C–1
TROOPER
DRIVELINE/AXLE
DRIVE SHAFT SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 4C–2 Shift On The Fly System and Associated
General Description . . . . . . . . . . . . . . . . . . . . . 4C–2 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–24
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–24
Front Hub and Disc (2WD Model) . . . . . . . . . 4C–4 Inspection and Repair . . . . . . . . . . . . . . . . . . 4C–26
Disassembled View . . . . . . . . . . . . . . . . . . . . 4C–4 Main Data and Specifications . . . . . . . . . . . 4C–31
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–32
Inspection and Repair . . . . . . . . . . . . . . . . . . 4C–6 Front Propeller Shaft . . . . . . . . . . . . . . . . . . . . . 4C–33
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–6 General Description . . . . . . . . . . . . . . . . . . . . 4C–33
Main Data and Specifications . . . . . . . . . . . 4C–9 Front Propeller Shaft and Associated Parts 4C–34
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–34
Front Hub and Disc (4WD Model) . . . . . . . . . 4C–11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–35
Disassembled View . . . . . . . . . . . . . . . . . . . . 4C–11 Disassembly (Except TOD 4×4) . . . . . . . . . 4C–36
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–11 Universal Joint Disassembly . . . . . . . . . . . . 4C–37
Inspection and Repair . . . . . . . . . . . . . . . . . . 4C–12 Inspection and Repair . . . . . . . . . . . . . . . . . . 4C–38
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–12 Universal Joint Reassembly . . . . . . . . . . . . . 4C–41
Main Data and Specifications . . . . . . . . . . . 4C–16 Reassembly (Except TOD 4×4) . . . . . . . . . . 4C–42
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–17 Main Data and Specifications . . . . . . . . . . . 4C–43
Front Drive Shaft Joint . . . . . . . . . . . . . . . . . . . 4C–18 Rear Propeller Shaft . . . . . . . . . . . . . . . . . . . . . 4C–44
Front Drive Shaft Joints Replacement . . . . 4C–18 General Description . . . . . . . . . . . . . . . . . . . . 4C–44
Front Axle Drive Shaft . . . . . . . . . . . . . . . . . . . 4C–19 Rear Propeller Shaft and Associated Parts 4C–44
Front Axle Drive Shaft and Associated Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–44
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–45
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–20 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–46
Inspection and Repair . . . . . . . . . . . . . . . . . . 4C–21 Universal Joint Disassembly . . . . . . . . . . . . 4C–47
Bushing Replacement . . . . . . . . . . . . . . . . . . 4C–21 Inspection and Repair . . . . . . . . . . . . . . . . . . 4C–48
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–22 Universal Joint Reassembly . . . . . . . . . . . . . 4C–49
Shift On The Fly System . . . . . . . . . . . . . . . . . 4C–24 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4C–50
Main Data and Specifications . . . . . . . . . . . 4C–51
4C–2 DRIVE SHAFT SYSTEM
Service Precaution
RESTRAINT SYSTEM(SRS). REFER TO THE SRS
sealant. UNLESS OTHERWISE SPECIFIED , do not
systems.
General Description
This publication contains essential removal, installation,
adjustment and maintenance procedures.
The front axle utilizes a central disconnect type front
axle/transfer case system.
The drive axles are completely flexible assemblies,
consisting of inner and outer constant velocity (CV) drive
shaft joints connected by an axle shaft.
For description of front propeller shaft and universal joint,
refer to Front Propeller Shaft in this section.
Diagnosis
Oil Leak At Front Axle Worn or defective oil seal. Replace the oil seal.
Front axle housing cracked. Repair or replace.
Oil Leak At Pinion Shaft Too much gear oil. Correct the oil level.
Oil seal worn or defective. Replace the oil seal.
Pinion flange loose or damaged. Tighten or replace.
Noises In Front Axle Drive Shaft Broken or worn drive shaft joints and Replace the drive shaft joints and
Joint bellows (BJ and DOJ). bellows.
“Clank” When Accelerating From Loose drive shaft joint to output shaft Tighten.
“Coast” bolts.
Damaged inner drive shaft joint. Replace.
Shudder or Vibration During Excessive drive shaft joint angle. Repair.
Acceleration
Worn or damaged drive shaft joints. Replace.
Sticking spider assembly (inner drive Lubricate or replace.
shaft joint).
Sticking joint assembly (outer drive Lubricate or replace.
shaft joint).
Vibration At Highway Speeds Out of balance or out of round tires. Balance or replace.
Front end out of alignment. Align.
Noises in Front Axle Insufficient gear oil. Replenish the gear oil.
Wrong or poor grade gear oil. Replace the gear oil.
Drive pinion to ring gear backlash Adjust the backlash.
incorrect.
Worn or chipped ring gear, pinion Replace the ring gear, pinion gear or
gear or side gear. side gear.
Pinion shaft bearing worn. Replace the pinion shaft bearing.
Wheel bearing worn. Replace the wheel bearing.
Differential bearing loose or worn. Tighten or replace.
Wanders and Pulls Wheel bearing preload too tight. Adjust the wheel bearing preload.
Steering gear out of adjustment. Adjust or replace the steering gear.
Tire worn or improperly inflated. Adjust the inflation or replace.
Front or rear suspension parts loose Tighten or replace.
or broken.
Front Wheel Shimmy Wheel bearing worn or improperly Adjust or replace.
adjusted.
Worn ball joint or bush. Replace the ball joint or bush.
Steering gear out of adjustment. Tighten or replace.
Tire worn or improperly inflated. Replace or adjust the inflation.
Shock absorber worn. Replace the shock absorber.
Front Hub and Disc (2WD Model)

Disassembled View
411RY00003
Legend (7) Hub and Disc Assembly

(1) Bolt (8) ABS Sensor Ring
(2) Cover and Gasket (9) Inner Bearing
(3) Packing (10) Oil Seal
(4) Lock Washer (11) Bolt
(5) Hub Nut (12) Wheel Pin
(6) Outer Bearing
Disassembly
1. Before disassembly, jack up the front of vehicle and
support frame with jack stands.
2. Remove the two bolts from the rear side of the
knuckle arm, then remove the brake caliper, with the
brake hose attached.
Use a wire to attach the brake caliper to the upper link.
Refer to Disk Brakes in Brake section.
3. Remove cover bolt. 11. Remove bolt.
4. Remove cover and gasket. 12. If necessary, replace the wheel pin in the following
5. Remove lock washer. manner.
6. Remove hub nut, using front hub nut wrench D Scribe mark(1) on hub to disc before disassembly
J–36827. to insure proper assembly.
411RS003
901RW054
7. Remove outer bearing. D Clamp hub and disc assembly in vise, using
8. Remove oil seal. protective pads. Remove six(6) disc-to-hub
retaining bolts.
9. Remove inner bearing.
10. Use a brass bar to remove the outer bearing outer
race(1), oil seal, inner bearing and inner bearing outer
race(2) from the hub.
411RS021
411RS002
D Place hub on a suitable work surface and remove NOTE: Be sure wheel stud is started squarely and seats
wheel studs, as required, using a hammer. completely.
411RS004 411RS005
2. Align index marks(1) and install hub to disc.

Check the following parts for wear, damage or other
D Hub
D Hub bearing
D Bearing outer race
D Disc
D Oil seal
Reassembly
D Place hub on a wood workbench or a block of wood
approx. 6” by 6” to protect the wheel stud ends and
threads.
D Install wheel stud, using a hammer.
411RS003
3. Install bolt. 5. Install inner bearing.
Tighten the bolts to the specified torque. Install the outer race by driving it into the hub by using
installer J–36829 and grip J–8092.
411RS023
411RS021
6. Install oil seal by using installer J–36830 and grip
J–8092.
Install the outer race by driving it into the hub by using
Apply Multipurpose grease NLGI No. 2 or equivalent
installer J–36828 and grip J-8092.
to the lip portion.
901RW056
901RW057
7. Apply Multipurpose grease NLGI No.2 in the hub and
bearing.
Hub 35 g (1.23 oz)
Outer bearing 10 g (0.35 oz)
Inner bearing 15 g (0.53 oz)
8. Install hub nut by using wrench J–36827.

Turn the place where there is a chamfer in the tapped
hole to the outer side, and attach the nut.
411RS011
9. Install lock washer.

D Turn the side with larger diameter of the tapered
bore to the vehicle outer side, then attach the
washer.
If the bolt holes in the lock plate are not aligned with
the corresponding holes in the nut, reverse the lock
plate. If the bolt holes are still out of alignment, turn
in the nut just enough to obtain alignment. Screw is
to be fastened tightly so its head may come lower
than the surface of the washer.
901RW054
Preload Adjustment
1. Tighten the hub nut to 29.4 N·m (21.7 lb ft), then
loosen the nut to the full.
2. Tighten the hub nut to the value given below,
using a spring scale on the wheel pin.
Bearing Preload
New bearing and New 19.6 – 24.5 N
oil seal (4.4 – 5.5 lb)
Used bearing and New 11.8 – 17.7 N
oil seal (2.6 – 4.0 lb)
If the measured bearing preload is outside the

specifications, adjust it by loosening or tightening
the bearing nut.
411RS012
10. Install the paking.

11. Install cover and tighten the cover bolt.
12. Install brake caliper and tighten fixing bolt.

E04RW00001
Special Tools
TOOL NO.
ILLUSTRATION
TOOL NAME
J–36827
Wrench; Hub nut
J–36829
J–36828
J–36830
Installer; Oil seal
Front Hub and Disc (4WD Model)

Disassembled View
411RW001
Legend (7) Outer Bearing

(1) Bolt (8) Bolt
(2) Cap (9) Hub and Disc Assembly
(3) Snap Ring and Shim (10) Wheel Pin
(4) Hub Flange (11) ABS Sensor Ring
(5) Lock Washer and Lock Screw (12) Inner Bearing
(6) Hub Nut (13) Oil Seal
Disassembly 3. Remove the disc brake caliper assembly and hang it

on the frame with wires. Refer to Disk Brakes in Brake
1. Before disassembly, select the 2WD position with the section.
4WD switch. 4. Remove Bolt.
2. Jack up the front of vehicle and support frame with 5. Remove cap.
jack stands.
6. Remove snap ring and shim.
7. Remove hub flange.
8. Remove lock washer and lock screw. D Place hub on a suitable work surface and remove
9. Use wrench J–36827, remove hub nut. the studs by using a hammer.
901RW054 411RS004
10. Remove hub and disc assembly.

11. Remove ABS sensor ring. Inspection and Repair
12. Remove outer bearing. Make necessary correction or parts replacement if wear,
13. Remove oil seal. damage, corrosion or any other abnormal condition are
14. Remove inner bearing. found through inspection.
Check the following parts.
15. Remove bolt , if necessary, replace the wheel pin in
D Hub
the following manner.
D Hub bearing oil seal
D Apply a scribe mark(1) to disc to hub.
D Knuckle spindle
D Clamp the hub and disc assembly in a vise, using
protective pads. Remove the 6 disc–to–hub D Disc
retaining bolts. D Caliper
D Shift on the fly system parts (Cap, Hub flange, Shim,
Snap ring)
D ABS sensor ring
For inspection and servicing of disc caliper and related
parts, refer to Disc Brakes in Brake section.
Reassembly
D Place the hub on a wood workbench or a block of
wood approx. 6” by 6” to protect the wheel stud
ends and threads.
411RS003
D Insert a wheel stud using a hammer. 3. Use installer J–36829 and grip J–8092, then install
Be sure the wheel stud is started squarely and the inner bearing by driving it into the hub.
seats completely.
901RW055
411RS005
4. Use installer J–36828 and grip J–8092 then install the
2. Align scribe marks(1) and attach the hub to the disc, outer bearing by driving it into the hub.
then tighten the bolts to the specified torque.
901RW056
411RS003
5. Apply grease (NLGI No.2 or equivalent) to the lip 8. Install hub nut.
portion, then install oil seal by using installer J–36830 Turn to the place where there is a chamfer in the
and grip J–8092. tapped hole to the outer side, then attach the nut by
using front hub nut wrench J–36827.
901RW057
6. Install ABS sensor ring, then tighten the bolts to the 901RW054
specified torque. Preload Adjustment

Torque: 18 N·m (13 lb ft) 1. Tighten the hub nut to 29 N·m (22 lb ft), then fully
7. Install hub and disc assembly. loosen the nut.
D Apply grease in the hub. 2. Tighten the hub nut to the value given below,
D Apply wheel bearing type grease NLGI No. 2 or using a spring scale on the wheel pin.
equivalent to the outer and inner bearing. New bearing and New oil seal
Grease Amount Bearing Preload: 20 N – 25 N (4.4 lb – 5.5 lb)
D Hub: 35 g (1.23 oz) Used bearing and New oil seal
D Outer bearing: 10 g (0.35 oz)
Bearing Preload: 12 N – 18 N (2.6 lb – 4.0 lb)
D Inner bearing: 15 g (0.53 oz)
If the measured bearing preload is outside the
specifications, adjust it by loosening or tightening the
bearing nut.
411RS009
Legend
(1) Inner Bearing 411RS011
(2) Hub
(3) Outer Bearing
9. Install lock washer and lock screw in the following 12. Install hub cap.
manner. 13. Tighten the bolts to the specified torque.
D Turn the side with larger diameter of the tapered Torque: 59 N·m (43 lb ft)
bore to the vehicle outer side, then attach the
washer.
D If the bolt holes in the lock plate are not aligned with
the corresponding holes in the nut, reverse the lock
plate.
D If the bolt holes are still out of alignment, turn in the
nut just enough to obtain alignment.
D Screw is to be fastened tightly so its head may
come lower than the surface of the washer.
411RS012
10. Apply adhesive (LOCTITE 515 or equivalent) to both

joining flange faces then install hub flange.
11. Install snap ring and shim.
D Adjust the clearance between the free wheeling hub
body and the snap ring.
Clearance: 0 mm–0.3 mm (0 in–0.012 in)
Shims Available: 0.2 mm, 0.3 mm, 0.5 mm,
1.0 mm (0.008 in, 0.012 in, 0.020 in, 0.039 in)
411RW002

E04RW001
Special Tools
TOOL NO.
ILLUSTRATION
TOOL NAME
J–36827
Wrench; Hub nut
J–36829
J–36828
J–36830
Installer; Oil seal
Front Drive Shaft Joint

Front Drive Shaft Joints Replace- 1. Open filler plug and make sure that the oil is up to the
plug port.
ment If the level oil is low, replenish with gear oil GL–5
D Refer to Front Drive Axle Assembly Replacement in grade.
this section, and refer to Front Hub and Disc in 2. Tighten the filler plug to specified torque.
Suspension section.
Front Hub Bearing Preload Check
Check the hub bearing preload at the wheel pin.
New bearing and new oil seal:
19.6 – 24.5 N (4.4 – 5.5 lb)
Used bearing and new oil seal:
11.8– 17.7 N (2.6 – 4.0 lb)
411RS001
Inspection Of Shift On The Fly System

Gear Oil
412RT002
Front Axle Drive Shaft

Front Axle Drive Shaft and Associated Parts
412RW003
Legend (13) Spacer

(1) Axle Case and Differential (14) Ball
(2) DOJ Case Assembly (15) Snap Ring
(3) Snap Ring (16) Ball Retainer
(4) Bearing (17) Ball Guide
(5) Snap Ring (18) Band
(6) Oil Seal (19) Bellows
(7) Bracket (20) Band
(8) DOJ Case (21) Band
(9) Circlip (22) Bellows
(10) Bolt (23) Band
(11) Drive Shaft Joint Assembly (24) BJ Shaft
(12) Snap Ring (25) Dust Seal
Disassembly 4. Remove drive shaft joint assembly.

5. Using snap ring pliers, remove the snap ring.
NOTE: For the left side, follow the same steps as right
side.
1. Raise the hooked end of the band (1) with a
screwdriver or equivalent.
412RS011
6. Remove spacer.
7. Remove the six balls (1) with a screwdriver or
equivalent.
412RS009
2. Remove band.
3. Pry off circlip (1) with a screwdriver or equivalent.
412RS012
412RS010
8. Using snap ring pliers, remove the snap ring (1) Inspection and Repair
fastening the ball retainer to the center shaft.
1. Drive shaft joint assembly
2. DOJ case, ball, ball guide, ball retainer
3. Bellows
4. Bearing
5. Dust seal, oil seal
Bushing Replacement
D Remove the bushings using a remover J–39378–1
and hammer.
412RS013
9. Remove ball retainer, ball guide and bellows.

10. Raise the hooked end of the band (1) with a
screwdriver or equivalent.
412RS015
D By using installer J–39378–2 and base J–39378–3,

press fit the bushings into the bracket.
412RS014
11. Remove band.

12. Remove bellows.
13. Remove dust seal.
14. Remove BJ shaft assembly.
15. Remove the mounting bracket fixing bolts, and then
remove DOJ case assembly from the axle case.
16. Remove snap ring and bearing.
17. Remove snap ring and oil seal.
18. Remove bracket.
412RS016
Reassembly 12. Using snap ring pliers, install the snap ring (1)
securing the ball retainer to the shaft.
1. Install DOJ case to bracket.
2. Install oil seal and fix snap ring.
3. Install bearing and fix snap ring.
4. Install bracket to axle case. Tighten the bracket bolt to
5. Apply 150g of the specified grease in BJ .
6. Install dust seal .
7. Apply a thin coat of grease to the shaft for smooth
installation then install bellows.
8. Install band. Note the setting direction. After
installation, check that the bellows is free from
distortion.
412RS013
13. Align the track on the ball (1) retainer with the window
in the cage, and install the six balls into position.
412RS017
9. Install another bellows and fix band.

10. Install the ball guide with the smaller diameter side
ahead onto the shaft.
11. Install ball retainer.
412RS018
14. Install spacer. 18. Install bellows. Adjust the air pressure within the
15. Install snap ring. bellows by inserting a screwdriver or equivalent, so
that it equals atmospheric pressure.
16. Enclose 150g of the specified grease in DOJ case,
then install drive shaft joint assembly. After
reassembly, move the DOJ longitudinally several
times to get to fit.
17. Install the circlip (1) so that open ends are positioned
away from the ball groove.
412RS021
19. Install Band. After installation, check that the bellows

is free from distortion.
412RS019
412RS020
Legend
(1) Outer Case
(2) Circlip
(3) Open Ends
Shift On The Fly System

Shift On The Fly System and Associated Parts
412RW004

(1) Filler Plug (9) Clutch Gear
(2) Bolt (10) Sleeve
(3) Oil Seal (11) Housing
(4) Snap Ring(External) (12) Front Axle Drive Shaft (LH side)with Bracket
(5) Inner Shaft Bearing (13) Bolt
(6) Snap Ring(Internal) (14) Actuator Assembly
(7) Inner Shaft (15) Bolt
Disassembly 4. Remove housing.

5. Remove sleeve.
1. Remove filler plug and gasket, drain oil.
2. Loosen mounting bracket fitting bolts and remove
front axle drive shaft from front axle case.
3. Remove Actuator Assembly and draw out actuator
ASM.
6. Remove clutch gear. 10. Remove inner shaft bearing by using a remover
7. Remove snap ring from front axle case by using snap J–37452 and press.
ring pliers. NOTE: Be careful not to damage the shaft.
412RW017
412RW015
8. Take out inner shaft from front axle case. 11. Remove needle bearing from inner shaft by using a
9. Remove snap ring from inner shaft by using snap ring remover J–26941 and sliding hammer J–2619–01.
pliers.
NOTE: Be careful not to damage the shaft.
412RW016
412RS045
12. Remove oil seal from front axle case.

NOTE: Be careful not to damage the front axle case.
Inspection and Repair Inner Shaft Run–Out

Inspect the removed parts. If there are abnormalities With both end centers supported, rotate the shaft slowly
such as wear and damage, take corrective action or and measure deflection with a dial gauge.
replace. Limit: 0.5 mm (0.02 in)
Visual Check NOTE: Do not heat the shaft to correct its bend.
1. Check and see if the inner shaft has any
abnormalities such as wear and damage.
412RS026
412RW014
Inner Shaft Bearing
2. When inspecting the inner shaft, be sure to check and
see if its splined part is twisted, worn, or cracked. If so,
replace with a new shaft. In case of an abnormality in
its gear part (a slide with sleeve), replace the shaft.
412RW006
Legend
(1) Inner Shaft Bearing
420RS008
(2) Inner Shaft
(3) Clutch Gear
1. Inspect the state of inner shaft bearing. If any

abnormality such as roughness is found, replace with
a new inner shaft bearing.
2. Insert a clutch gear and check the state of needle
bearing.
3. If there is an abnormality such as roughness, replace
the needle bearing.
Sleeve Condition Clutch Gear Condition
Check and see that there is no wear, damage, or cracking Check and see that there is no wear, damage, cracking,
in the sleeve. or any other abnormality in the clutch gear.
NOTE: Close inspection of the groove and inner gear are
required because those are important parts.
Clutch Gear Function
Sleeve Function
412RW010
If there is an abnormality such as roughness when

operated in combination with sleeve, replace the clutch
412RW011
gear.
Operate the sleeve with the inner shaft combined with the
clutch gear. If roughness is felt, replace the sleeve. NOTE: When inspecting, gear oil should be applied to the
contact surface of gear.
NOTE: Gear oil should be applied to the contact surface
of gear.
Clutch Gear Journal Diameter
Check the width of sleeve center groove.
Make sure of the size illustrated.
Limit: 7.1 mm (1.28 in)
Limit: 36.98 mm (1.456 in)
412RW022
412RW009
Actuator
Check and see that there is no damage, cracking, or other
abnormality.
Functional Check
412RW007
Disconnect the shift position switch and make sure of

function with a vacuum of –400 mmHg applied to Ports A
and B, in accordance with the table below.
412RW021
State Port A Port B Function
C –400 mmHg A/P E
D A/P –400 mmHg F
If there is an abnormality, replace the actuator as an

assembly.
NOTE:
1. If the actuator works under –400mmHg or less, there
is no functional problem.
412RW013
2. Be careful not to permit the entry of water or dust into 2. Force a new needle bearing into inner shaft by using a
the ports of the actuator. installer J–41694 and grip J–8092.
Dimensional Check
Measure illustrated sizes 1, 2, and 3.
Limit
1=64.1 mm (2.52 in)
2=6.7 mm (0.26 in)
3=6.7 mm (0.26 in)
412RS051
3. Place a new snap ring(internal) in inner shaft.

Force a new inner shaft bearing into the inner shaft by
using a installer J–37452 and press.
412RS037
Reassembly
1. Install the new oil seal which has been immersed in
differential gear oil, by using an oil seal installer
J–41693 and grip J–8092.
412RS044
4. Install snap ring(external).

NOTE: Be careful not to damage the inner shaft.
5. Clean the housing contact surface of the front axle
case and insert inner shaft assembly into the front
axle case.
NOTE: Be careful not to damage seal.
412RS043
6. Install snap ring (internal) in the groove of front axle 10. Tighten bolts to specified torque.
case. Torque: 116N·m(85 lb ft)
NOTE: Be sure to install the snap ring properly. 11. Clean the actuator contact surface with the housing
then Install and tighten shift position switch to
specified torque.
12. Apply liquid gasket to the contact surface on the
actuator side.
412RW017
7. Apply differential gear oil to clutch gear, then install

clutch gear.
8. Apply differential gear oil to sleeve, then install
sleeve.
9. Clean contact surface with the front axle and actuator 412RW012
mounting surface. Apply liquid gasket to the contact 13. Align shift arm with the groove of sleeve and install the
surface on the front axle case, then install in the actuator.
housing.
14. Tighten bolts to specified torque.
Torque: 13N·m(113 lb ft)
15. Install front axle drive shaft and mounting bracket.
Tighten fitting bolts to specified torque.
16. Pour specified amount of differential gear oil to filler
plug.
Front Differential
Oil Capacity: 1.4lit (1.48US qt)
Actuator Housing
Oil Capacity: 0.12lit(0.13US qt)
17. Install filler plug through gasket and tighten to
specified torque.
Torque: 7.8N·m (58lb ft)
412RW023

Front drive axle oil capacity 1.4 liter (1.48 US qt)(Differential)
0.12 liter (0.13 US qt)(Actuator Housing:Shift on the fly)
Type of lubricant GL–5 (Multi grade type) Refer to chart in General Information
Axle shaft type Constant velocity joint(Birfield joint type and double offset joint)
E04RW004
Special Tools
TOOL NO. TOOL NO.
TOOL NAME TOOL NAME
J–39378
Remover and Installer; J–8092
Front Axle mount Grip
bushing
J–37452
Inner shaft bearing
J– 26941
Remover;Bearing needle
J–2619–01
Hammer; Sliding
J–41693
Installer; Oil seal
J–41694
Installer; Bearing needle
Front Propeller Shaft
General Description
Since the propeller shaft is balanced carefully, welding or Alignment marks should be applied to each propeller
any other modifications are not permitted. shaft before removal.
401RW002
Front Propeller Shaft and Associated Parts
401RW058
Legend (4) Front Propeller Shaft (with TOD)

(1) Bolt, Nut and Washer (Front Axle Side) (5) Coupling
(2) Front Propeller Shaft (6) LJ Constant Velocity Joint
(3) Bolt, Nut and Washer (Transfer Side) (7) BJ Constant Velocity Joint
Removal
1. Jack up the vehicle and support it on the chassis
stands.
2. Gear shift lever should be placed in neutral position
and parking brake released.
3. Remove the exhaust and transfer protectors.
NOTE: Apply alignment marks on the flange at the front
propeller shaft both front and rear side.
401RS020
401RW053 401RW051
Installation
NOTE: Never install the shaft assembly backwards.
Completely remove the black paint from the connecting
surface of flange coupling on each end of propeller shaft.
Clean so that no foreign matter will be caught in between.
1. Align the mark which was applied at removal. Install
front propeller shaft and tighten the bolts to the
specified torque.
2. Install the exhaust and transfer protectors.
3. After installing the propeller shaft, be sure to apply
black paint (1) to exposed area (other than
connecting surface) of the entire surface of flange
coupling .
401RW052
4. Remove bolt, nut and washer (Front axle side).

5. Remove bolt, nut and washer (Transfer side).
6. Remove front propeller shaft.
NOTE: If equipped with torque on demand (TOD), when
removing, installing or carring for front propeller shaft, be
sure to wind a piece of cloth round the part of the boot with
which fittings may interfere so that the boot can be
protected. The boot may be damaged if bending force is
applied to the constant velocity joint of the shaft.
401RS019
Disassembly (Except TOD 4×4)
401RW057
Legend (2) Seal

(1) Sleeve Yoke (3) Tube Assembly
1. Apply alignment marks (1) on the sleeve yoke and 2. Remove seal.
tube assembly then remove sleeve yoke. 3. Remove tube assembly.
401RW056
Universal Joint Disassembly
401RW055
Legend (3) Snap Ring

(1) Flange Yoke (4) Needle Roller Bearing
(2) Spider (5) Grease Fitting
1. Apply alignment marks (1) on the yokes of the 2. Tap out the needle roller bearing by gently striking the
universal joint, then remove snap ring. shoulder of the yoke, using a mallet or a copper
hammer.
401RS028
401RS006
3. Make sure of proper position for reinstallation by
applying setting marks, then remove spider .

damage, corrosion or any other abnormal condition is
NOTE: When any part of the journal assembly (spider,
needle roller bearing) requires replacement, be sure to
replace the entire assembly.
1. Spider
2. Needle roller bearing
3. Yoke
4. Flange
5. Constant velocity joint
401RS027
Outside Diameter of Spider Pin

Play in Splines in Normal Direction of
Standard: 17.00 mm (0.669 in)
Rotation
Limit: 16.90 mm (0.665 in) Check the amount of play between the sleeve yoke (1)
and the propeller shaft spline (2) in the direction of
rotation, using a pointed feeler gauge.
Standard: 0.073 – 0.156 mm (0.003 – 0.006 in)
Limit: 0.3 mm (0.012 in)
401RS007
Propeller Shaft Run–out

Support the ends of the propeller shaft on V-blocks (2)
and check for run–out by holding the probe of a dial
indicator (1) in contact with the center part of the shaft. If 401RS009
the amount of run–out is beyond the standard value for

assembly, correct with a bench press or replace the shaft
with a new propeller shaft assembly.
Limit: 0.5 mm (0.02 in)
Play in Universal Joint
Limit: Less than 0.1 mm (0.004 in)
401RW049
Boot of Constant Velocity Joint

401RS010 Check the boot (2) for crack, damage and grease leak,
and the boot band (1) for loosening and damage. Check
Constant Velocity Joint the both sides of the joint and make sure that there is no
leak of grease from the cover press-in parts(3).
NOTE: LJ and BJ constant velocity joints are
unremovable types. Check the joint for play and the boot
for damage, wear, and leak of grease. If abnormality is
found, replace propeller shaft as an assembly.
Play in Constant Velocity Joint

Fix the shaft in a vise throrgh pieces of wood, and try to
move the joint vertically, right and left, and back and forth
to make sure of smooth motions and no remarkable play.
401RW048
401RW050
2. Set a dial gage at right angle near the inner
circumference and check the run-out of the flange.
Limit: 0.15 mm (0.006 in)
401RW047
Front Axle Flange Run-out

1. Set a dial gage at right angle near the outer
401RW045
circumference of the flange face and check the
run-out of the flange face. 3. If vibration is felt during the 4H AUTO drive, disconnct
the propeller shaft at the front axle. Reinstall the
Limit: 0.15 mm (0.006 in) propeller shaft at 60°, 120°, 180°, 240°, and 300°
and conduct test drive in each position and check if
there is vibration.
401RW046
401RW044
Universal Joint Reassembly 4. Align setting marks (1) and join the yokes.
1. Install spider to flange yoke. Be sure to install the

spider by aligning the setting marks made during
disassembly.
2. Apply a molybdenum–disulfide grease or a
multi–purpose type grease NLGI No. 2 to inside of the
bearing cap.
Grease Amount: Approx. 1.2 g (0.042 oz)
401RS028

NOTE: Discard used snap rings and install new ones.
When the bearing cap is in position, select and attach a
snap ring of suitable thickness so that the end play of the
spider pin is held within 0.1 mm (0.004 in).
Snap ring thickness and Identification color
401RS011 1.5 mm (0.059 in); Blue
3. Using either a mallet (or copper hammer) or a press, 1.53 mm (0.060 in); White
install the needle roller bearing into the yoke so that 1.59 mm (0.063 in); Yellow
the snap ring can be installed in its groove.
1.62 mm (0.064 in); Green
CAUTION: The needle roller bearing cannot be 1.68 mm (0.066 in); Not colored
installed smoothly if it is set at an incorrect angle
with the flange and excessive hammering will NOTE: Be sure to use snap rings of the same thickness
damage the needle roller bearing. on both sides.
401RS012
Reassembly (Except TOD 4×4)
401RW057
Legend (2) Seal

1. Discard used seal and install new one.

2. Align the alignment marks and install tube assembly
to sleeve yoke.

Engine 6VE1(3.5 L)
Transmission M/T A/T A/T with TOD
Hollow steel tube with yoke and spider type universal Hollow steel tube with
Construction
joints. constant velocty joints.
Outside diameter 40.0 mm (1.57 in) 40.0 mm (1.57 in) 40.0 mm (1.57 in)
Length 559 mm (22.01 in) 559 mm (22.01 in) 577 mm (22.72 in)
E04RW005
Rear Propeller Shaft
General Description
Since the propeller shaft is balanced carefully, welding or Alignment marks should be applied to each propeller
any other modifications are not permitted. shaft before removal.
401RW003
Rear Propeller Shaft and Associated Parts
401RW059
Legend (2) Rear Propeller Shaft

(1) Bolt, Nut and Washer (3) Bolt, Nut and Washer
Removal 2. Gear shift lever should be placed in neutral position

and parking brake released.
1. Jack up the vehicle and support it on the chassis
stands. NOTE: Apply alignment marks on the flange at the rear
propeller shaft both front and rear side.
401RS023
3. Remove bolt, nut and washer (Rear axle side).

4. Remove bolt, nut and washer (Transfer side).
5. Remove rear propeller shaft.
Installation
NOTE: Never install the shaft assembly backwards.
1. Completely remove the black paint from the
connecting surface of flange coupling on each end of
propeller shaft. Clean so that no foreign matter will be
caught in between.
2. Align the mark which is applied at removal .
Install rear propeller shaft and tighten the bolts to the
specified torque.
3. After installing the propeller shaft, be sure to apply
black paint (1) to exposed area (other than
connecting surface) of the entire surface of flange
coupling .
401RS022
Disassembly
401RW057
Legend (2) Seal

1. Apply alignment marks (1) on the sleeve yoke and 2. Remove seal.
tube assembly then remove sleeve yoke. 3. Remove tube assembly.
401RW056
Universal Joint Disassembly
401RW054

(1) Flange Yoke (4) Needle Roller Bearing
(2) Spider with Grease Fitting (5) Grease Fitting
1. Apply alignment marks (1) on the yokes of the 2. Tap out the needle roller bearing by gently striking the
universal joint, then remove snap ring. shoulder of the yoke, using a mallet or a copper
hammer.
401RS028
401RS006
3. Make sure of proper position for reinstallation by
applying setting marks, then remove spider with
grease fitting.

damage, corrosion or any other abnormal condition is
NOTE: When any part of the journal assembly (spider,
needle roller bearing, grease fitting) requires
replacement, be sure to replace the entire assembly.
1. Spider
2. Needle roller bearing
3. Yoke
4. Flange
401RS008
Outside Diameter of Spider Pin
Standard: 17.00 mm (0.669 in) Play in Splines in Normal Direction of
Rotation
Limit: 16.90 mm (0.665 in)
Check the amount of play between the sleeve yoke (1)
and the propeller shaft spline (2) in the direction of
rotation, using a pointed feeler gauge.
Standard: 0.073 – 0.156 mm (0.003 – 0.006 in)
Limit: 0.3 mm (0.012 in)
401RS007
Propeller Shaft Run-out

Support the ends of the propeller shaft on V-blocks (2)
and check for run-out by holding the probe of a dial
indicator (1) in contact with the center part of the shaft. If 401RS009
the amount of run-out is beyond the standard value for

assembly, correct with a bench press or replace the shaft
with a new propeller shaft assembly .
Limit: 0.5 mm (0.02 in)
Play in Universal Joint
Limit: Less than 0.1 mm (0.004 in)
401RS012
4. Align setting marks (1) and join the yokes.

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

1. Install spider to flange yoke. Be sure to install the
spider by aligning the setting marks made during
disassembly.
2. Before installing needle roller bearing, apply a
molybdenum–disulfide grease or a multi–purpose
type grease NLGI No. 2 to inside of the bearing cap.
Grease Amount: Approx. 1.2 g (0.042 oz)
401RS028

NOTE: Discard used snap rings and install new ones.
When the bearing cap is in position, select and attach a
snap ring of suitable thickness so that the end play of the
spider pin is held within 0.1 mm (0.004 in).
Snap ring thickness and identification color
1.5 mm (0.059 in): Blue
1.545 mm (0.061 in): White
401RS011
3. Using either a mallet (or copper hammer) or a press, 1.59 mm (0.063 in): Yellow
install the needle roller bearing into the yoke so that 1.635 mm (0.064 in): Green
the snap ring can be installed in its groove. 1.68 mm (0.066 in): Not colored
CAUTION: The needle roller bearing cannot be NOTE: Be sure to use snap rings of the same thickness
installed smoothly if it is set at an incorrect angle on both sides.
with the flange and excessive hammering will
damage the needle roller bearing.
Reassembly
401RW057
Legend (2) Seal

1. Discard used seal and install new one.

2. Align the alignment marks and install tube assembly
to sleeve yoke.

Engine 6VE1(3.5 L)
Transmission M/T A/T A/T with TOD
Construction Hollow steel tube with yoke and spider type universal joints.
Outside diameter 68.9 mm (2.71 in) 68.9 mm (2.71 in) 68.9 mm (2.71 in)
Length 1093 mm (43.03 in) 1093 mm (43.03 in) 1075 mm (42.32 in)
E04RW006
TRANSFER CASE (STANDARD TYPE) 4D1–1
TROOPER
DRIVELINE/AXLE
TRANSFER CASE (STANDARD TYPE)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 4D1–1 Detent, Shift Arm, and Interlock Pin
General Description . . . . . . . . . . . . . . . . . . . . . 4D1–2 (Transfer Case Assembly) . . . . . . . . . . . . . . . 4D1–14
Transfer Rear Oil Seal . . . . . . . . . . . . . . . . . . . 4D1–4 Disassembled View . . . . . . . . . . . . . . . . . . . . 4D1–14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D1–4 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D1–14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D1–4 Inspection and Repair . . . . . . . . . . . . . . . . . . 4D1–16
Transfer Case Assembly . . . . . . . . . . . . . . . . . 4D1–5 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D1–16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D1–5 Transfer Case Assembly . . . . . . . . . . . . . . . . . 4D1–18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D1–5 Disassembled View . . . . . . . . . . . . . . . . . . . . 4D1–18
Transfer Rear Case Assembly . . . . . . . . . . . . 4D1–7 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D1–19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D1–7 Inspection and Repair . . . . . . . . . . . . . . . . . . 4D1–21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D1–8 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D1–25
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D1–11 Main Data and Specifications . . . . . . . . . . . . . 4D1–31
Inspection and Repair . . . . . . . . . . . . . . . . . . 4D1–12 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D1–34
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D1–12
Service Precaution
systems.
4D1–2 TRANSFER CASE (STANDARD TYPE)
General Description
M/T model
A07RW019
A/T model
A07RW001
The transfer case is used to provide a means of providing

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

Removal
1. Disconnect the rear propeller shaft from the transfer
case side.
2. Remove end nut and rear companion flange, use the
companion flange holder J–8614–11 to remove the
end nut.
220RS016
4. Rear companion flange and end nut.

5. Install the rear companion flange and O–ring.
6. Use the companion flange holder J–37221 to install a
new end nut and tighten to the specified torque.
266RW001
7. Use the punch J–39209 to stake the end nut at two
3. Use the universal puller to remove the rear spots.
companion flange and O–ring. NOTE: Be sure to confirm that there is no crack at the
4. Remove the oil seal from the transfer case. staked portion of the end nut after staking.
Installation
1. Install oil seal and apply engine oil to the oil seal outer
surfaces.
2. Apply the recommended grease (BESCO L2) or
equivalent to the oil seal lip.
3. Use the oil seal installer J–39208 to install the rear
seal to the transfer rear case.
266RS001
8. Connect the rear propeller shaft to the transfer case
and tighten to the specified torque.
Torque: 63 N·m 46 (lb ft)
266RW002
Transfer Case Assembly

Removal 10. Remove transfer control lever.
11. Disconnect the 4WD switch and speed sensor
NOTE: Before removing transmission & transfer harness connector and 2WD–4WD actuator harness
assembly from vehicle, change the transfer mode to 2WD connector from the transmission harness.
by pushing button switch on dash panel.
12. Remove transmission–transfer bolt and support the
1. Disconnect the battery ground cable. transfer case with a transmission jack.
2. Drain the transfer case fluid. 13. Remove four transmission–transfer bolts and the
3. Remove transfer protector. three nuts.
4. Remove rear propeller shaft. 14. Remove the transfer case assembly from the vehicle.
5. Remove the rear and front propeller shaft from the
transfer case side. Installation
6. Disconnect the four oxygen sensor connectors from To install, follow the removal steps in the reverse order,
the transmission harness. noting the following points:
7. Remove the right and left catalytic converter 1. Install transfer case assembly and apply a thin coat of
assemblies and exhaust pipe. molybdenum disulfide grease to the input shaft
8. Remove the transfer control lever knob. spline.
9. Remove the selector lever assembly. Refer to
Selector Lever in the Section 7A.
2. Tighten the transmission–transfer bolt to the 3. Tighten the exhaust pipe to exhaust manifold bolt to
specified torque. the specified torque.
Torque: 46 N·m (34 lb ft) Torque: 67 N·m (49 lb ft)
4. Tighten the exhaust pipe flange bolt to the specified
torque.
5. Tighten the propeller shaft bolt to the specified torque.
6. Tighten the transfer protector bolt to the specified
torque.
260RW001
256RW026
Transfer Rear Case Assembly

Removal 10. Pull the 2WD–4WD actuator assembly with
2WD–4WD shift rod.
1. Remove the speedometer sensor.
2. Remove the plate.
3. Remove the speedometer driven gear bushing and
driven gear.
NOTE: Apply a reference mark to the driven gear bushing
before removal.
4. Remove front companion flange.
5. Remove rear companion flange, use the flange
companion holder J–8614–11 to remove the end nut.
262RW009
220RW027
6. Remove the front and rear companion flange.
Legend
NOTE: Use the universal puller to remove the rear
(1) Shift Rod: 2WD–4WD (Position: 2WD)
companion flange.
(2) 2WD–4WD Actuator Assembly
7. Remove control box assembly. (3) Pull
8. Disconnect the actuator breather hose from the (4) Rear Case Assembly
2WD–4WD actuator assembly. (5) Position: 4WD
(6) Mode: 2WD
220RW085
9. Remove the 2WD–4WD actuator assembly bolts.

11. Off set the actuator assembly. 2. Install transfer case assembly and apply the
recommended liquid gasket (LOCTITE 17430) or its
equivalent to the transfer rear case fitting faces.
220RW028
12. Remove the actuator assembly.

220RS017
3. Perform the following steps before fitting the transfer

rear case:
1. Shift the high–low shift to the 4H side.
2. Turn the select rod counterclockwise so that the
select block projection A may enter into the
2WD–4WD shift block.
3. The cut–away portion of the select rod head (9)
should align with that of the rear case hole’s
stopper (10).
220RW029
Legend
(7) Position: 4WD
(8) Mode: 2WD
13. Remove transfer case assembly.

14. Remove transfer rear case assembly.
Installation
1. Install transfer rear case assembly. 230RW004
4. Tighten the transfer rear case bolts to the specified

torque.
5. Shift the 2WD–4WD shift rod (11) to the 4WD side.
6. Join the rod grooves of 2WD–4WD actuator 11. Install rear companion flange.
assembly (12) and shift rod (11). 12. Install front companion flange, use the companion
flange holder J–8614–11 to tighten the flange nuts to
the transfer case.
220RW030
Legend
(11) Shift Rod: 2WD–4WD (Position: 4WD) 262RW009
(12) 2WD–4WD Actuator Assembly (Mode: 2WD) 13. Tighten the new transfer flange nuts to the specified
torque.
(13) Rear Case Assembly
Torque
7. Push the 2WD–4WD actuator assembly (12) with Rear companion flange: 167 N·m (123 lb ft)
2WD–4WD shift rod (11) till the shift rod (11) reaches Front companion flange: 137 N·m (101 lb ft)
the 2WD position.
14. Use the punch J–39209 to stake the rear companion
flange nut at two spots.
220RW031
Legend 266RS001
(14) Position: 2WD

(15) Mode: 2WD
8. Tighten the 2WD–4WD actuator bolts to the specified

torque.
9. Connect the actuator breather hose to actuator.
10. Install control box assembly.
19. Install the plate (6) to the transfer rear case and
tighten to the specified torque.
20. Install the speedometer sensor and tighten to the
specified torque.
266RW002
15. Stake the front companion flange nut at one spot.

NOTE: Be sure to confirm that there is no crack at the
staked portion of the flange nut after staking.
16. Install the O–ring (8) to the speedometer driven gear
bushing (7).
17. Install the driven gear to the speedometer driven gear
bushing (7). 225RW005
18. Install the speedometer driven gear assembly to the

transfer rear cover.
Disassembly
226RW131
Legend (5) Bearing Snap Ring

(1) Rear Output Shaft Assembly (6) Ball
(2) Rear Output Shaft (7) Speedometer Drive Gear
(3) Bearing Snap Ring (8) Ball Bearing
(4) Ball Bearing (9) Transfer Rear Case (with oil seal)
1. Remove bearing snap ring, use a pair of snap ring

pliers to remove the snap ring.
226RS060
2. Remove the rear output shaft assembly from the Reassembly
transfer rear case.
3. Remove ball bearing, use a bench press and the 1. Install transfer rear case (with oil seal).
bearing remover J–22912–01 to remove the ball Oil seal replacement
bearing. D Remove the oil seal from the transfer rear case.
D Apply engine oil to the oil seal outer surfaces.
D Fill in recommended grease (BESCO L2) or
equivalent in the oil seal lip.
D Use the oil seal installer to install J–39208 to the
rear oil seal to the transfer rear case.
226RS061
4. Remove speedometer drive gear.

5. Remove ball.
7. Remove ball bearing.
8. Remove rear output shaft, use a bench press and the 220RS019
bearing remover J–22912–01 to remove the ball 2. Install rear output shaft.
bearing. 3. Install ball bearing, use the ball bearing installer
J–37223 and the adapter J–37486–A to install the ball
bearing.
226RS062
9. Remove transfer rear case (with oil seal).

262RW021
4. Install bearing snap ring.

Inspection and Repair 5. Install ball.
Refer to “TRANSFER CASE ASSEMBLY” in this section
for inspection and repair.
6. Install speedometer drive gear.
226RS064
7. Install ball bearing, use the ball bearing installer

J–37223 to install the ball bearing.
226RS065
8. Install the rear output shaft assembly to the transfer

rear case.
NOTE: The snap ring must be fully inserted into the
transfer rear case snap ring groove.
Detent, Shift Arm, and Interlock Pin (Transfer Case Assembly)

Disassembled View
262RW010
Legend (9) Shift Arm

(1) Transfer Case (10) 2WD–4WD Shift Rod
(2) Detent Ball, Spring and Plug (11) Spring Pin and Bridge
(3) Spring (12) Select Rod Assembly
(4) Interlock Pin (13) Spring Pin
(5) 4WD Indicator Switch (14) High–Low Shift Rod
(6) Shift Block (15) Shift Arm
(7) Spring Pin (16) Shift Block
(8) Spring
Disassembly
1. Remove detent ball, spring and plug.
2. Remove spring pin and bridge, use a spring pin 10. Remove spring, use a magnetic tool to remove the
remover to remove the spring pin from the bridge. interlock pin from the transfer case.
262RW011 262RS005
3. Remove spring pin. 11. Remove select rod assembly.

4. Remove spring. 12. Remove spring pin.
5. Engage the 2WD–4WD sleeve with front output gear. 13. Remove high–low shift rod, use a spring pin remover
Remove the spring pin from the block. Remove the to remove the shift arm spring pin from the shift arm
shift rod. and shift block. Remove the high–low shift rod.
262RW022 262RS006
6. Remove shift arm. 14. Remove shift arm.

7. Remove shift block. 15. Remove shift block.
8. Remove 4WD indicator switch. 16. Remove transfer case.
9. Remove interlock pin.

Refer to “TRANSFER CASE ASSEMBLY” in this section
for inspection and repair.
Reassembly
1. Install transfer case.
2. Install shift block.
3. Install shift arm.
4. Install high–low shift rod.
5. Engage the High–Low sleeve with the 4H (1) side.
6. Install the spring pin to the shift block and shift arm.
262RW013
Legend
(2) 2WD–4WD
262RW012
(3) 4H Side
7. Install select rod assembly. (4) Interlock pin
8. Install spring. (5) 2WD
9. Engage the High–Low sleeve with the 4H side and (6) 4WD
install the interlock pin (4) in the proper direction. (7) Rod: 2–4
10. Install the shift rod: 2WD–4WD (2) with interlock pin (8) Rod: H–L
pushed in. (9) 4H
(10) 4L
(11) 4×2
(12) 4×4
11. Install 4WD indicator switch and tighten to the

specified torque.
12. Install shift block.
13. Install shift arm.
14. Install 2WD–4WD shift rod.
15. Install spring.
16. Engage the 2WD–4WD sleeve with the 4WD side and
install the spring pin.
262RW022
17. Install spring pin and bridge.

18. Install detent ball, spring and plug and tighten the plug

Disassembled View
226RW132
Legend (22) Counter Gear

(1) Transfer Case (with oil seal) (23) Sub–Gear (anti–lash plate)
(2) Bearing Snap Ring (24) Belleville Spring
(3) Front Output Gear Assembly (25) Spacer
(4) Ball Bearing (26) Ball Bearing
(5) Front Output Shaft (27) Snap Ring
(6) Stopper Plate (28) Counter Gear Assembly
(7) 2WD–4WD Clutch Hub and Assembly (29) Bearing Snap Ring
(8) Block Ring (30) Input Shaft Assembly
(9) Outside Ring (31) Input Shaft
(10) Inside Ring (32) Ball Bearing
(11) Front Output Gear (33) Snap Ring
(12) Needle Bearing (34) Plate
(13) Sub–Gear (anti–lash plate) (M/T) (35) Ball
(14) Belleville Spring (M/T) (36) Bearing Collar
(15) Spacer (M/T) (37) Needle Bearing
(16) Sub–Gear Snap Ring (M/T) (38) Transfer Input Gear
(17) Bearing Collar (39) High–Low Clutch Hub and Sleeve Assembly
(18) Ball Bearing (40) Lock Nut
(19) Bearing Snap Ring (41) Ball Bearing
(20) Snap Ring (42) Bearing Snap Ring
(21) Ball Bearing
Disassembly 7. Remove the input shaft assembly from the transfer

case.
2. Remove ball bearing, use a bearing remover J–37217
and puller J–37487 to remove the ball bearing.
265RW001
8. Remove high–low clutch hub and sleeve.

9. Remove transfer input gear, use the universal puller
to remove the high–low clutch hub and sleeve, and
262RW016 transfer input gear.
3. Install the front companion flange temporarily.
4. Use the Companion flange holder J–8614–11 and
lock nut wrench J–37219 to remove the lock nut.
226RS070
10. Remove needle bearing.
226RW130
5. Remove the front companion flange.

11. Remove bearing collar. 17. Remove front output gear assembly, use a pair of
snap ring pliers to expand the bearing snap ring and
use a plastic hammer to tap the front output gear
assembly free.
226RS071
12. Remove ball.

13. Remove plate.
262RS009
14. Remove ball bearing, use a bench press and the ball
18. Remove bearing snap ring.
bearing remover J–22912–01 to remove the ball
bearing. 19. Remove ball bearing.
20. Remove bearing collar.
21. Remove sub–gear snap ring. (M/T)
22. Remove spacer. (M/T)
23. Remove belleville spring. (M/T)
24. Remove sub–gear (anti–lash plate). (M/T)
25. Remove front output gear.
26. Remove needle bearing, use a bench press and the
bearing remover J–22912–01 to remove the parts
above.
265RS002
15. Remove input shaft.

16. Remove bearing snap ring.
262RS010
27. Remove inside ring.

28. Remove outside ring.
29. Remove block ring.
30. Disassemble the 2WD–4WD clutch hub and sleeve 37. Remove ball bearing, use a bench press and the
assembly. bearing remover J–22912–01 to remove the ball
D Springs (1) bearing.
D Inserts (2) 38. Remove snap ring, use a pair of snap ring pliers to
remove the snap ring.
D Clutch Hub (3) 39. Remove ball bearing, use a bench press and the
D Sleeve (4) bearing remover J–22912–01 to remove the ball
bearing.
226RW133
31. Remove stopper plate. 226RS073
40. Remove spacer.

NOTE: Do not reuse the stopper plate. 41. Remove belleville spring.
32. Remove ball bearing, use the ball bearing remover 42. Remove sub–gear (anti–lash plate).
J–22912–01 to remove the ball bearing.
43. Remove counter gear.

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

34. Remove bearing snap ring. 1. Use an inside dial indicator to measure the gear inside
35. Remove the counter gear assembly from the transfer diameter.
case.
36. Remove snap ring, use a pair of snap ring pliers to
remove the snap ring.
2. If the measured value exceeds the specified limit, the Bearings
gear must be replaced.
1. Inspect the condition of all the needles and ball
Gear inside diameter bearings. Wash bearings thoroughly in a cleaning
Standard : 48.000–48.013 mm (1.8898–1.8903 in) solvent. Apply compressed air to the bearings.
Limit : 48.10 mm (1.894 in) NOTE: Do not allow the bearings to spin. Turn them
slowly by hand. Spinning bearings may damage the
rollers.
2. Lubricate the bearings with a light oil and check them
for roughness by slowly turning the race by hand.
Ball Bearing Play
1. Use a dial indicator to measure the ball bearing play.
2. If the measured value exceeds the specified limit, the
ball bearing must be replaced.
Limit : 0.2 mm (0.008 in)
226RS040
Clutch Hub Spline Play

1. Set a dial indicator to the clutch hub to measured.
2. Move the clutch hub as far as possible to both the right
and the left.
Note the dial indicator reading.
clutch hub must be replaced.
Clutch hub spline play 226RS043
Standard : 0–0.1 mm (0–0.004 in)

Limit : 0.2 mm (0.008 in)
226RS042
Block Ring and Insert Clearance Clutch Hub and Insert Clearance
1. Use a vernier caliper to measure the clearance 1. Use a thickness gauge to measure the clearance
between the block ring and the insert. between the clutch hub and the insert.
2. If the measured value exceeds the specified limit, the 2. If the measured value exceeds the specified limit, the
block ring and the insert must be replaced. clutch hub and the insert must be replaced.
Block ring and insert clearance Clutch hub and insert clearance
Standard : 3.46–3.74 mm (0.136–0.147 in) Standard : 0.01–0.19 mm (0.0004–0.0075 in)
Limit : 4.0 mm (0.158 in) Limit : 0.3 mm (0.012 in)
226RS037 226RS038
2WD–4WD Synchronizer (3–Cone) Detent Springs

1. Use a thickness gauge to measure the clearance 1. Inspect the springs for distortion, cracks or wear.
between the block ring and the dog teeth. Replace if these conditions are present.
2. If the measured value exceeds the specified limit, the Detent Spring Free Length
2WD–4WD synchronizer assembly must be
replaced. 1. Use a vernier caliper to measure the detent spring
free length.
Block ring and insert clearance
Standard : 1.5 mm (0.059 in)
Limit : 0.8 in (0.031 in)
226RW142
2. If the measured value is less than the specified limit,
the detent spring must be replaced.
Detent spring free length
Detent ball
Limit : 22.8 mm (0.898 in)
Interlock pin
Limit : 1.53 mm (0.060 in)
220RS013
Shift Arm
1. Inspect the shift arms for wear, distortion or scoring.
Replace if these conditions are present.
Shift Arm Thickness
1. Use a micrometer to measure the shift arm thickness.
the shift arm must be replaced.
Shift arm thickness
220RW035
Standard : 9.60–9.85 mm (0.378–0.388 in)
Detent Spring Tension
Limit : 9.0 mm (0.354 in)
1. Use a spring tester to measure the detent spring
tension.
the detent spring must be replaced.
Detent spring free length
Detent ball
Compressed height : 18.7 mm (0.736 in)
Standard : 68.6–88.2 N (15.4–19.8 lb)
Interlock pin
Compressed height : 11.5 mm (0.453 in)
Standard : 9.8 N (2.2 lb)
230RS006
Reassembly
1. Install transfer case (with oil seal).
Input shaft oil seal (1) replacement
1. Remove the oil seal from the transfer case.
2. Apply engine oil to the oil seal outer surfaces.
3. Apply recommended grease (BESCO L2) or
4. Use the oil seal installer J–38592 to install the oil
seal to the transfer case.
220RW033
2. Install counter gear.

3. Install sub–gear and apply chassis grease (3) to the
sub–gear and the counter gear thrust surfaces.
220RW032
Front output shaft oil seal (2) replacement

2. Apply engine oil to the oil seal outer surfaces.
3. Apply recommended grease (BESCO L2) or
4. Use the oil seal installer J–38594 to install the oil
seal to the transfer case.
226RW134
4. Install belleville spring.

5. Install spacer.
6. Install ball bearing.
7. Select a snap ring that will allow the minimum axial
play.
Clearance : 0–0.1 mm (0–0.004 in)
Snap ring availability: 3. Measure the sub–gear preload.

Thickness Color–coding Preload : 59–98 N (13–22 lb)
1.50 mm (0.059 in) White
1.55 mm (0.061 in) Yellow
1.60 mm (0.063 in) Blue
8. Use a pair of snap ring pliers to install the snap ring to

the counter gear.
226RS075

11. Install the counter gear assembly to the transfer case.
12. Install bearing snap ring, use a pair of snap ring pliers
to install the snap ring to the transfer case.
226RS170
transfer case snap ring groove.
13. Install front output shaft.
14. Install ball bearing, use a bench press to install the
ball bearing to the front output shaft.
226RS021
Sub–Gear (anti–lash plate) Preload

1. Hook a length of piano wire (4) over one of the
sub–gear (5) teeth.
262RS012
2. Attach the other end of the piano wire (4) to a 15. Install stopper plate.
spring balancer.
16. Assemble the clutch sleeve and hub assembly. 18. Install a new stopper plate and the clutch sleeve and
hub assembly to the front output shaft.
226RW140
17. Engage the springs in the same insert with the open 226RW135
ends away from each other. Legend

(6) Front Output Gear
19. The clutch hub face (with the heavy boss) must be
facing the front output gear side.
20. Use a bench press to slowly force the clutch sleeve
and hub assembly together with the stopper plate into
place.
21. Align the inserts with the block ring insert grooves.
Install the block ring to the clutch sleeve and hub
assembly.
22. Install outside ring.
23. Install the outside ring, inside ring and needle bearing
to the front output gear and bearing collar.
NOTE: Coat all parts with transmission oil before
installing them.
226RW141
226RW139
24. Install needle bearing.

25. Install front output gear.
26. Install sub–gear (anti–lash plate). (M/T)
27. Install belleville spring. (M/T) 32. Install bearing snap ring and select a snap ring that
28. Install spacer and apply engine oil to the thrust will allow the minimum axial play.
surfaces of the sub–gear, the belleville spring, and the Clearance : 0–0.1 mm (0–0.004 in)
spacer. (M/T)
Snap ring availability:
Snap ring thickness Color coding
1.55 mm (0.061 in) White
1.60 mm (0.063 in) Yellow
1.65 mm (0.065 in) Blue
1.70 mm (0.067 in) Pink
1.75 mm (0.069 in) Green
1.80 mm (0.071 in) Brown
1.85 mm (0.073 in) Red
1.90 mm (0.075 in) Orange
262RW060
29. Install sub–gear snap ring. (M/T)

30. Install bearing collar, use a bench press to install the
needle bearing collar together with the front output
gear.
262RS015
262RS014
226RS021
33. Use a pair of snap ring pliers to install the snap ring to 39. Install ball.
the output shaft. 40. Install bearing collar.
Sub gear (anti lash plate) preload (M/T) 41. Install needle bearing.
1. Hook a length of piano wire (4) over one of the 42. Install transfer input gear.
sub–gear (5) teeth. 43. Install high–low clutch hub and sleeve and the clutch
2. Attach the other end of the piano wire to (4) a hub face (with the heavy boss) must be facing the
spring balancer. transfer input gear side (7).
3. Measure the sub–gear preload.
Preload: 59–98 N (13–22 lb)
(M/T)
226RW136
44. Install input shaft assembly.

45. Install the snap ring to the input shaft.
46. Install the input shaft assembly to the transfer case.
226RS075
47. Install the snap ring to the transfer case.
34. Install front output gear assembly.
35. Install bearing snap ring, use a pair of snap ring pliers NOTE: The snap ring must be fully inserted into the
to install the snap ring to the transfer case. transfer case snap ring groove.
48. Install the front companion flange temporarily and use
the flange holder J–8614–11 and lock nut wrench
transfer case snap ring groove.
J–37219 to install the lock nut.
36. Input shaft.
37. Install ball bearing, use a bench press to install the
ball bearing to the input shaft.
226RW137
49. Use the punch to stake the lock nut at one spot.
265RS003
38. Install plate.

50. Install ball bearing, use a suitable drift and hammer to
install the ball bearing.
226RS079


Type Synchronized type gears shifting between the 2 and 4 wheel drive mode.
Constant mesh type gears shifting between “low” and “high”.
Control method Remote control with the gear shift lever on the floor for gear shifting
between “low and high” .
Electric control with the button switch on the instrument panel for gear
shifting between the 2 and 4 wheel drive mode.
Gear ratio High; 1.000
Low; 2.050
Oil capacity 1.45 lit. (1.53 U.S. quart)
Type of lubricant Engine oil
Refer to chart in Section 0
E07RW008
E07RW009
E07RW010
Special Tools
PART NO. PART NO.
PART NAME PART NAME
J–22912–01 J–38594
Bearing Front output shaft oil
remover/installer seal installer
J–38592
J–39208
Transfer case oil seal
Rear oil seal installer
installer
J–37219 J–37486–A
Mainshaft nut wrench Bearing installer adapter
J–37223
J–8614–11
Rear output shaft and
Flange holder
bearing installer
J–37217
J–39209
Mainshaft end bearing
Punch, end nut
remover
PART NO.
ILLUSTRATION
PART NAME
J–37487
Puller
J–8092
Driver handle
TRANSFER CASE (TOD) 4D2–1
TROOPER
DRIVELINE/AXLE
TRANSFER CASE (TOD)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 4D2–1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–16
Transfer Case Assembly . . . . . . . . . . . . . . . . . 4D2–2 Sprocket and Mechanical Lock . . . . . . . . . . . . 4D2–18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–2 Disassembled View . . . . . . . . . . . . . . . . . . . . 4D2–18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–3 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–18
Transfer Rear Oil Seal . . . . . . . . . . . . . . . . . . . 4D2–5 Output Shafts and Shift Control Shaft . . . . . . 4D2–20
Transfer Rear Oil Seal and Associated Disassembled View . . . . . . . . . . . . . . . . . . . . 4D2–20
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–5 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–5 Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–23
TOD ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–7 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–7 Inspection and Repair . . . . . . . . . . . . . . . . . . 4D2–26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–7 Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–30
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–8 Disassembled View . . . . . . . . . . . . . . . . . . . . 4D2–30
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–8 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–30
Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–9 Output Shafts and Shift Control Shaft . . . . . . 4D2–33
Disassembled View . . . . . . . . . . . . . . . . . . . . 4D2–9 Disassembled View . . . . . . . . . . . . . . . . . . . . 4D2–33
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–9 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–33
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–10 Sprocket and Mechanical Lock . . . . . . . . . . . . 4D2–36
Transfer Cover Assembly . . . . . . . . . . . . . . . . 4D2–12 Disassembled View . . . . . . . . . . . . . . . . . . . . 4D2–36
Disassembled View . . . . . . . . . . . . . . . . . . . . 4D2–12 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–36
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–12 Clutch Pack and Clutch Cam . . . . . . . . . . . . . 4D2–38
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–14 Disassembled View . . . . . . . . . . . . . . . . . . . . 4D2–38
Transfer Case Assembly Clutch Pack and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–38
Clutch Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–16 Main Data and Specifications . . . . . . . . . . . . . 4D2–40
Disassembled View . . . . . . . . . . . . . . . . . . . . 4D2–16 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D2–42

systems.
4D2–2 TRANSFER CASE (TOD)

Removal
F07RW025
1. Disconnect the battery cable (-).

2. Remove transfer protector.
3. Remove rear propeller shaft.
4. Remove front propeller shaft.
6. Uncouple the shift control rod from the select lever Installation
assembly.
Pay attention to the following points.
1. Apply grease (Besco L2) or equivalent to the input
shaft spline.
256RW028
7. Place the select lever assembly near the end.

8. Remove transfer control lever.
261RW024
9. Remove breather hose. 2. Mount the transfer case.
10. Remove the exhaust pipe set bolts and nuts, and shift
the pipe to the end.
11. Remove the right cross member hanger and shift the
proper shaft to the end.
260RW006
12. Unplug the 4WD switch connector from the

transmission harness.
13. Unplug the transfer connector from the top of the
transfer case.
14. Support the transfer case with a jack.
15. Remove the four bolts and three nuts from the
transfer case.
3. Tighten the transfer case bolts (see the figure below).
261RW004
4. Tighten propeller shaft bolt.

Torque : 63 N·m (46 lb ft)
Transfer Rear Oil Seal

Transfer Rear Oil Seal and Associated Parts
261RW005
Legend
(1) Oil Seal
(2) End Nut and Rear Companion Flange
Removal
1. Uncouple the rear propeller shaft from the transfer
case.
2. Using the flange holder J-8614-11, remove the end
nut.
3. Using the universal puller, remove the rear
companion flange and O-ring.
4. Remove the oil seal from the transfer rear case.
Installation
1. Apply oil to the circumference of the oil seal. Fill the oil
seal lip with grease (Besco L2).
261RW006
Legend
(1) Inside
(2) Outside
2. Using the oil seal installer J-42804, attach the oil seal.
NOTE: When attaching the oil seal, pay attention to the
direction.
260RW007
6. Connect the rear propeller shaft to the transfer case

Torque : 63 N·m 46 (lb ft)
261RW035
3. Mount the rear companion flange, O-ring , washer,

and nuts to the transfer in this order.
4. Using the flange holder J-8614-11, set the end nut.
5. Using the punch J-39209, stake the end nut at two
places.
NOTE: Check the staked end nut is free from cracks.
266RW020
TOD ECU
1. Disconnect the battery cable (-). 1. Perform the removal step in reverse order.
2. Move the passenger seat forward and remove the
second seat foot rest (1).
3. Unplug the connector from the ECU (2).
4. Remove the set bolts and detach the ECU (2) from
the bracket.
F07RW021
Unit Repair
Inspection Power GND
Before disassembling and after assembling, check the Check that there is a continuity between the power GND
following items on the transfer connector terminals. pin (terminal 7) and transfer case. If not, replace the
grounding wire.
No. NAME CONTENTS
1 Ref . (Ref . ) Rear speed sensor refer- Resistance of electromagnetic coil
ence output Check the resistance between electromagnetic clutch
2 Ref . (Frt . ) Front speed sensor refer- solenoid (terminal 8) and power GND (terminal 7). If not,
ence output replace the electromagnetic coil.
Standard : 1.4 ∼ 2.0W
3 SW GND SW GND
Allowable : 1.0 ∼ 5.0W
4 4H SW (+) 4H SW plus terminal
5 Rer . (+) Rear speed sensor plus
6 Frt . (+) Front speed sensor plus
7 POWER GND Power GND
8 SOL (+) Electromagnetic solenoid
9 COM (–) (Ref .) Rear speed sensor GND
10 COM (–) (Frt .) Front speed sensor GND
11 NC
12 4L SW (+) 4L SW plus terminal
810RW002
4H and 4L switches
Check whether the 4H switch (terminals 4 and 7) and 4L
switch (terminals 12 and 3 ) work as specified in the table
below. If yes, the continuity is established on these
switches. If not, check the switches, shift rails, transfer
case, and rear cover, and replace the failed parts.
Position High Neutral 4L
4H SW OFF ON OFF
4L SW OFF ON ON
Transfer Case
Disassembled View
266RW004
Legend (4) Spring Pin

(1) Front Companion Flange (5) Transfer Case Assembly
(2) 4H and 4L Switch, Grounding Cable, and (6) Transfer Cover Assembly
Center Connector (7) Rear Companion Flange
(3) Offset Lever
Disassembly
1. Remove the drain plug from the transfer case and
drain the oil.
2. Disconnect the 4H and 4L switch and grounding
cable.
3. Remove the clip fixing the harness.
4. Remove front companion flange and using the flange
holder J-8614-11, remove the flange nut.
5. Remove rear companion flange and using the flange
holder J-8614-11, remove the flange nut.
266RW005
6. Remove the offset lever set bolt on the right side. 8. Remove the offset lever.
261RW015 261RW017
7. Remove the offset lever lock spring pin. 9. Remove the sixteen bolts and detach the transfer
cover assembly from the transfer cable assembly.
NOTE: When removing the spring pin, pay attention to
the recess position of the pin. NOTE: When removing the transfer cover assembly, pay
attention not to damage the oil seal.
Reassembly
1. Apply liquid gasket (Loctite 598 or equivalent)
uniformly to the mating face that contacts the transfer
case.
261RW016
261RW023
2. Tighten the sixteen bolts with the specified torque. 10. Using the punch J-39209, securely stake the flange
Torque : 31 N·m (23 lb ft) nut at two places
3. Wind the sealing tape around the drain plug thread NOTE: Check the staked flange nut is free from cracks.
and tighten the plug with the specified torque.
4. Install offset lever.
5. Mount the offset lever to the transfer shift and attach
the spring pin.
266RW020
261RW016
6. Install rear and front companion flange.

7. Attach the O-ring and washer to the companion
flange.
NOTE: Securely push the O-ring to the dent of the
companion flange, and then attach the washer.
8. Use the flange holder J-8614-11 to tighten the flange
nuts to transfer case.
9. Tighten the flange nut with the specified torque.
260RW007
11. Fix the harness with the clip.

12. Tighten the 4L and 4H switch to the specified torque.
13. Fill the transfer case with ATF II or III (1.9 liters).
14. Wind the sealing tape around the filler plug thread and
tighten the plug with the specified torque.
Transfer Cover Assembly

Disassembled View
261RW007
Legend (4) Speed Gear and Tone Wheel

(1) Coil Assembly (5) Ball Bearing
(2) Snap Ring (6) Transfer Cover Assembly
(3) Ball Bearing (7) Front and Rear Speed Sensors
Disassembly
261RW047
2. Remove ball bearing. 5. Using a terminal pull-out tool or an equivalent tool,
3. Strike the speed gear and tone wheel with a rod or push down the lock to unlatch the terminal for the coil
other appropriate tool from the outside of the transfer assembly, and pull the terminal out.
cover assembly, and remove the ball bearing and NOTE: Pay attention not to damage other terminals.
speed gear and tone wheel.
NOTE: Pay attention not to damage the speed gear
teeth.
261RW032
6. Remove the set bolts of the cam&coil housing from

the outside of the transfer cover assembly. Remove
266RW018
the housing from the transfer cover.
4. Remove the stopper plate on the back with a
precision screwdriver or other appropriate tool
starting from the small lock of the plate.
NOTE: Pay attention not to damage the stopper plate
during the work.
261RW030
261RW042
7. Using the bearing remover J-42805 and slide Reassembly
hammer J-2619-01, remove the ball bearing for the
front output shaft. 1. Remove the oil seal from the transfer cover assembly.
2. Apply oil to the circumference of the new oil seal and
fill the lip with grease (Besco L2 or equivalent).
3. Using the oil seal installer J-42804, attach the oil seal
to the transfer cover assembly.
901RW087
8. Remove the bolts and front and rear speed sensors.

NOTE: Pay attention not to damage the speed sensors
during the work.
261RW035
4. Apply grease to the seal ring of each front and rear

speed sensor, and mount the sensor carefully.
5. Tighten the bolt with the specified torque.
Torque : 5 N·m (43 lb in)
NOTE: Pay attention not to mount the front (or rear)
sensor to the rear (or front) sensor position.
6. Mount the ball bearing (1) for the front output shaft flat
as shown in the figure.
261RW033
261RW008
7. Mount the coil assembly and tighten the set nuts with
8. Plug the terminal in the central connector.
NOTE: Pay attention not to damage other terminals.
9. Install speed gear and tone wheel.
10. Mount the ball bearing (2) flat as shown in the figure.
261RW009
11. Using snap ring pliers, attach the snap ring to the
transfer cover assembly.
NOTE: Securely mount the snap ring to the groove of the
transfer cover assembly.
Transfer Case Assembly Clutch Pack and Clutch Cam

Disassembled View
266RW006
Legend (5) Wave Spring

(1) Clutch Pack Assembly (6) Cam Pulley
(2) Insulator Washer (7) Cam Ball
(3) Armature Plate (8) Cam and Coil Housing
(4) Snap Ring (9) Thrust Bearing
Disassembly
1. Remove thrust bearing.
2. Remove cam and coil housing.
NOTE: When the cam and coil housing is removed, the
cam balls may be detached together with the housing.
Pay attention not to lose the ball.
3. Remove cam ball.
266RW013
4. Remove cam pulley.
5. Remove wave spring.
NOTE: Pay attention not to damage the snap ring.
266RW009
7. Remove the armature plate.

8. Remove the insulator washer.
9. Remove the clutch pack assembly as a package.
266RW017
Sprocket and Mechanical Lock

Disassembled View
266RW008
Legend (7) Lock-up Fork

(1) Strainer (8) Chain
(2) Hose (9) Lower Drive Sprocket
(3) Oil Pump Assembly (10) Front Tone Wheel
(4) Thrust Washer (11) Drive Sprocket
(5) Mechanical Lock Hub (12) Sprocket Spacer
(6) Lock-up Sleeve
Disassembly
1. Remove sprocket spacer.
2. Remove front tone wheel.
3. Remove drive sprocket.
4. Remove lower drive sprocket.
5. Remove the drive sprocket, lower drive sprocket, and
chain together from the front and rear output shafts.
266RW010
6. Remove mechanical lock hub.

7. Remove lock-up fork.
8. Remove the spring retainer from the connection
between rail shaft and lock-up fork.
9. Remove lock-up sleeve.
261RW018
10. Remove thrust washer.

11. Remove the magnet from the strainer set position
together with the oil pump assembly.
12. Remove the strainer from the oil pump assembly.
13. Remove the hose from the oil pump assembly.
Output Shafts and Shift Control Shaft

Disassembled View
261RW010
Legend (10) Cam Assembly

(1) Transfer Case Assembly (11) Snap Ring
(2) Detent Spring (12) Washer
(3) Front Output Shaft (13) Cam
(4) Reduction Hub (14) Cam Pilot Block
(5) Output Shaft (15) Shifter Shaft Assembly
(6) Lock-up Roll Assembly (16) Shifter Lever Shaft
(7) Spring Pin (17) Snap Ring
(8) Spring Pin (18) Reduction Lever Assembly
(9) Reduction Fork (19) Snap Ring
Disassembly 6. Remove the spring pin that fixes the reduction fork.
1. Remove output shaft.
261RW020
7. Remove the reduction fork.

266RW011
8. Remove the lock-up roll.
2. Remove detent spring.
3. Remove the cam pilot block set bolts.
4. Remove the cam pilot block assembly and cam
assembly.
5. Remove the spring pin that fixes the reduction hub
together.
261RW029
10. Remove the washer.

11. Remove the cam.
12. Remove the cam pilot block.
261RW019
13. Using snap ring pliers, attach the snap ring.
261RW021
14. Remove the reduction lever assembly.

15. Remove the snap ring.
16. Remove the shifter lever shaft.
17. Remove the front output shaft.
266RW012

Transfer Case
Disassembled View
265RW002
Legend (7) Ball Bearing

(1) Transfer Case (8) Spring Ring
(2) Ball Bearing (9) Thrust Plate
(3) Ring Gear (10) Carrier Assembly
(4) Snap Ring (11) Snap Ring
(5) Input Shaft and Carrier Assembly (12) Circular Hub
(6) Snap Ring
Disassembly 4. Remove the snap ring from the transfer case.
1. Remove ball bearing (for front output shaft).

2. Open the snap ring from the gap on the carrier
assembly.
261RW036
5. Using snap ring pliers, remove the snap ring before

the ball bearing.
261RW040
3. While opening the snap ring, remove the input shaft,

ball bearing, carrier assembly, and thrust plate from
the transfer case.
265RW009
261RW037
6. Using the bearing remover J-22912-01, remove the 10. Remove the circular hub.
ball bearing from the input shaft. 11. Remove the snap ring before the ring gear.
265RW004
261RW025
7. Remove the thrust plate. 12. Using the special tool J-42806, remove the ring gear.
8. Remove the carrier assembly.
NOTE: Removing the ring gear needs a high-load press.
9. Remove the snap ring from the carrier assembly. This means the transfer case may be damaged. To
remove and replace the ring gear, it is recommended that
the transfer case assembly should be replaced.
265RW006
261RW011
D If the measurement exceeds the limit, replace the
reduction hub.
Standard : 3.05-3.30 mm (0.120-0.130 in)
Allowable limit : 2.5 mm (0.098 in)
265RW007

When wear, damage, or any other defects are observed
during the inspection, the part or parts must be repaired or
replaced. Wash all the parts with clean detergent, and 265RW005
check that old oil, metallic particles, dirt, or foreign Lock-up Sleeve
materials are completely removed. Blow the air into oil Mount the lock-up hub, drive sprocket assembly, and
holes and grooves to remove foreign materials or residual lock-up sleeve to the output shaft.
detergent. If the lock-up sleeve does not move smoothly, replace
Chain the sleeve.
D Check whether the face that contacts the sprocket is NOTE: Apply ATF to the area engaging the gear.
free from excessive wear or damage. If defects are
observed, replace the part. Thickness of Lock-up Sleeve
D If the chain interference mark is found on the inside D If the measurement exceeds the limit, replace the
wall of the transfer cover or the chain is so slack that a lock-up sleeve.
skipped engagement occurs between the chain and Standard : 7.16-7.32 mm (0.282-0.288 in)
sprocket, replace the chain.
Sprocket
D Check whether the sprocket tooth surface is
excessively worn or damaged, and there is evidence
of burrs, chipping, wear, or damage on the gear
spline. Remove minor flaws or scratches with oil
stone. If excessive wear or damage is observed,
replace the part.
D If excessive wear or damage is observed on the
sprocket inside sliding surface, replace the part.
Gear
Check whether the gear tooth surface is excessively
worn or damaged, and there is evidence of burrs,
chipping, wear, or damage on the gear spline.
Remove minor flaws or scratches with oil stone. If
excessive wear or damage is observed, replace the
part.
Thickness of Reduction Hub
D Measure the thickness with a micrometer. 266RW014
Reduction Fork Bearing
Check the reduction fork and shaft for wear, distortion, Check the profile of the needle, roller, ball, and thrust
and scratches. If defects are observed, replace the bearings. Wash the bearings with clean detergent
parts. completely, and dry with air.
Thickness of Reduction Fork NOTE: If the bearing is rotated excessively, the rollers
D If the measurement exceeds the limit, replace the may be damaged. So, rotate the bearing slowly with your
reduction fork. hand. Apply grease to the bearing, and check the
smoothness of the bearing while slowly rotating the race
Standard : 3.41-3.79 mm (0.134-0.149 in) with your hand.
Allowable limit : 4.4 mm (0.173 in) Allowable limit : 0.23 mm (0.009 in)
261RW026
226RW143
Lock-up Fork Lock-up Fork Spring
D Check the lock-up fork and shaft for wear, distortion, Check the lock-up fork spring for distortion, cracking,
and scratches. If defects are observed, replace the and wear. If defects are observed, replace the part.
parts.
Free Length of the Lock-up Fork Spring
Thickness Lock-up Fork
D If the measurement exceeds the limit, replace the
If the measurement exceeds the limit, replace the spring.
lock-up fork.
Standard : 6.99-7.09 mm (0.275-0.279 in)
220RW045
261RW027
Tension of Lock-up Fork Spring Multi Plate Disk Clutch
D If the measurement exceeds the limit, replace the D If the burned, mirror-surfaced clutch facing, or
spring. (When compressed to 41.4 mm) scraping is observed on the clutch plates, clutch
Standard : 27.1-33.8 N {2.76-3.45 kg} housing, armature plate, and insulator washer,
replace the part or parts.
Allowable limit : 24.5 N {2.5 kg}
266RW003
014RW048
Tension of Detent Spring Assembly Coil Assembly

D If the measurement exceeds the limit, replace the D Check the resistance of the coil with a tester. If
spring. N {kg} (When compressed by 3 mm from the defects are observed, replace the assembly.
free length) * (ordinary temperature)
Standard : 139 N -203 {14.2-20.7 kg} Standard : 1.4∼2.0 W
Allowable limit : 130 N {13.3 kg} Allowable limit : 1.0∼5.0 W
261RW041 261RW031
Oil Pump
D Remove foreign materials from the strainer. If the
strainer is damaged, replace it.
D If the area into which the shaft is inserted is
excessively worn or damaged, replace the pump.
Cam Pulley, Cam Ball, and Cam&Coil

Housing
D Check the cam balls and cam for excessive wear or
damage. If defective, replace the parts. 4H and 4L
switches.
261RW049
Switch 4H Switch 4L Switch The

Stroke Signal Signal correspon
ding
osition
position
B to Switch A to C of
266RW016
Body transfer
The Parts 4H and 4L Switch lever
D Check the continuity of 4H and 4L switch. 1 Open Open High
2 Open Close 4L
3 Close Close Neutral
261RW003
Transfer Case
Disassembled View
265RW002
Legend (7) Ball Bearing

(1) Transfer Case (8) Spring Ring
(2) Ball Bearing (9) Thrust Plate
(3) Ring Gear (10) Carrier Assembly
(5) Input Shaft and Carrier Assembly (12) Circular Hub
(6) Snap Ring
Reassembly
2. Apply the circumference of the new oil seal and fill the
lip with grease (Besco L2 or equivalent).
3. Using the front output shaft oil seal installer J-42807, 5. Using the special tool J-42809, press-fit the ring gear.
attach the oil seal to the transfer case. Pay attention to the following points.
D Identify the correct direction of gear.
D Do not damage the gear.
D Do not press-fit the ring gear slantingly.
D Press-fit the ring gear to the innermost.
D Remove burrs generated by press-fitting.
D If the transfer case has serrations, match them with
those of the gear and press-fit the gear.
261RW014
4. Using the input shaft (main) J-42808 oil seal installer,

attach the oil seal to the transfer case.
261RW013
261RW012
261RW034

7. Install circular hub.
8. Attach the snap ring to the carrier.
9. Mount the carrier assembly to the transfer case. 14. Using the snap ring pliers, open the snap ring from the
10. Check the direction of thrust plate and mount it to the gap on the input shaft and carrier assembly and
input shaft. securely attach the part.
261RW038
265RW008
11. Mount the ball bearing to the input shaft so that the 15. Install ball bearing (for front output shaft)
snap ring will be attached to the input shaft.
265RW003
12. Attach the snap ring to the input shaft.

13. Attach the snap ring to the transfer case.
Output Shafts and Shift Control Shaft

Disassembled View
261RW010
Legend (10) Cam Assembly

(1) Transfer Case Assembly (11) Snap Ring
(2) Detent Spring (12) Washer
(3) Front Output Shaft (13) Cam
(4) Reduction Hub (14) Cam Pilot Block
(5) Output Shaft (15) Shifter Shaft Assembly
(6) Lock-up Roll Assembly (16) Shifter Lever Shaft
(7) Spring Pin (17) Snap Ring
(8) Spring Pin (18) Reduction Lever Assembly
(9) Reduction Fork (19) Snap Ring
Reassembly
1. Apply ATF to the inside of the ball bearing.
2. Mount the front output shaft to the transfer case. 4. Mount the cam to the cam pilot.
5. Attach the washer to the cam pilot block and fix the
washer with the snap ring.
266RW012
3. Mount the reduction lever assembly to the shifter

lever shaft and fix the assembly with the snap ring. 261RW029
6. Mount the reduction fork to the lock-up roll.

7. Attach the spring pin to fix to the reduction fork.
261RW021
261RW020
8. Mount the lock-up assembly and reduction hub to
together to transfer case assembly.
9. Mount the shifter shaft assembly.
261RW019
10. Tighten the cam pilot block set bolts to the specified
torque.
11. Tighten the detent spring to the specified torque.
261RW022
12. Apply ATF to the needle bearing inside the output

shaft assembly.
13. Mount the output shaft to the transfer case.
Sprocket and Mechanical Lock

Disassembled View
266RW008
Legend (7) Lock-up Pork

(1) Strainer (8) Chain
(2) Hose (9) Lower Drive Sprocket
(3) Oil Pump Assembly (10) Front Tone Wheel
(4) Thrust Washer (11) Drive Sprocket
(5) Mechanical Lock Hub (12) Sprocket Spacer
(6) Lock-up Sleeve
Reassembly
1. Install oil pump.
2. Attach the hose and strainer to the oil pump.
3. Mount the oil pump to the output shaft and attach the
magnet to the strainer set position.
4. Install thrust washer.
5. Attach the spring to the lock-up fork.
6. Mount the lock-up sleeve and fork together to the
output shaft and shifter roll assembly.
7. Mount the spring retainer to the lock-up fork.
261RW018
8. Install mechanical lock hub.

9. Apply ATF to the chain.
10. Engage the chain to both sprockets.
11. Mount the chain and sprocket assembly to both the
output shafts.
266RW010
Clutch Pack and Clutch Cam

Disassembled View
266RW006
Legend (5) Wave Spring

(1) Clutch Pack Assembly (6) Cam Pulley
(2) Insulator Washer (7) Cam Ball
(3) Armature Plate (8) Cam and Coil Housing
(4) Snap Ring (9) Thrust Bearing
Reassembly
1. Mount the clutch pack assembly to which the multi
plate disk clutch is already installed to the output
shaft.
NOTE: Mount the clutch pack assembly while adjusting
the phase of both the clutch housing and drive sprocket.
2. Install the insulator washer.
3. Install the armature plate.
4. Using snap ring pliers, attach the snap ring.
266RW009
5. Install the wave spring.

6. Install the cam pulley.
7. Place a ball on each groove of the cam pulley.
266RW013
8. Install the cam and coil housing.

9. Thrust bearing.

Leading Particulars
Type Transfer case with low range reduction mechanisn
2H Rear wheel drive
TOD Electronically controlled torque split four wheel drive
4L Low-speed mechanical lock-up four wheel drive
Control system Floor direct control
Gear ratio H 1.000
L 2.480
Oil quantity, Lit 1.9
Oil ATF DEXRON-IIE or ATF DEXRON-III
E07RW011
E07RW012
Special Tools
TOOL NO. TOOL NO.
TOOL NAME TOOL NAME
J–8614–11 J–42806
Flange Holder Ring Gear Replacer
J–42807
J–42804
Front Out Oil Seal
Rear Oil Seal Installer
Installer
J–42808
J–39209
Input Shaft Oil Seal
Punch
Installer
J–42805 J–42809
Bearing Remover Ring Gear Installer
J–2619–01
Slide Hammer
J–22912–01
Bearing Remover
BRAKE CONTROL SYSTEM 5A–1
TROOPER
BRAKES
CONTENTS
Brake Control System . . . . . . . . . . . . . . . . . . . . 5A–1 Power-Assisted Brake System . . . . . . . . . . . . 5C–1
Anti–lock Brake System . . . . . . . . . . . . . . . . . . 5B–1 Parking Brakes . . . . . . . . . . . . . . . . . . . . . . . . . 5D–1
BRAKE CONTROL SYSTEM

CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 5A–2 Diagnostic Trouble Codes (DTCs) . . . . . . . 5A–24
General Description . . . . . . . . . . . . . . . . . . . . . 5A–3 Chart B-1 With the key in the ON position
System Components . . . . . . . . . . . . . . . . . . . 5A–3 (Before starting the engine). Warning light
(W/L) is not activated. . . . . . . . . . . . . . . . . . 5A–27
Electronic Hydraulic Control Unit (EHCU) . 5A–3 Chart B-2 EHCU Abnormality (DTC 14) . . . 5A–27
ABS Warning Light . . . . . . . . . . . . . . . . . . . . 5A–4 Chart B-3 Power Voltage Drop (DTC 15) . . 5A–28
Wheel Speed Sensor . . . . . . . . . . . . . . . . . . 5A–4 Chart B-4 CLASS-2 Communication Line
G-Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–4 Abnormality (DTC 16) . . . . . . . . . . . . . . . . . 5A–28
Normal and Anti-lock Braking . . . . . . . . . . . 5A–4 Chart B-5 G-Sensor Circuit (DTC 21) . . . . . 5A–28
Chart B-6 Abnormal Transmission Input
Brake Pedal Travel . . . . . . . . . . . . . . . . . . . . 5A–4 (DTC 23) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–29
Acronyms and Abbreviations . . . . . . . . . . . . 5A–4 Chart B-7 Transfer Monitor (DTC 24) . . . . . 5A–30
General Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 5A–5 Chart B-8 EHCU Pump Motor And Motor
General Information . . . . . . . . . . . . . . . . . . . . 5A–5 Relay Circuit (DTC 32) . . . . . . . . . . . . . . . . . 5A–30
Chart B-9 EHCU Pump Valve And Valve
ABS Service Precautions . . . . . . . . . . . . . . . 5A–5 Relay Circuit (DTC 35) . . . . . . . . . . . . . . . . . 5A–31
Computer System Service Precautions . . . 5A–5 Chart B-10 FL Isolation Solenoid Valve
General Service Precautions . . . . . . . . . . . . 5A–5 Abnormality (DTC 41) . . . . . . . . . . . . . . . . . 5A–31
Note on Intermittents . . . . . . . . . . . . . . . . . . . 5A–5 Chart B-11 FL Dump Solenoid Valve
Abnormality (DTC 42) . . . . . . . . . . . . . . . . . 5A–31
Test Driving ABS Complaint Vehicles . . . . . 5A–5 Chart B-12 FR Isolation Solenoid Valve
“ABS” Warning Light . . . . . . . . . . . . . . . . . . . 5A–6 Abnormality (DTC 43) . . . . . . . . . . . . . . . . . 5A–32
Normal Operation . . . . . . . . . . . . . . . . . . . . . 5A–6 Chart B-13 FR Dump Solenoid Valve
Basic Diagnostic Flow Chart . . . . . . . . . . . . 5A–6 Abnormality (DTC 44) . . . . . . . . . . . . . . . . . 5A–32
Basic Inspection Procedure . . . . . . . . . . . . . 5A–7 Chart B-14 Rear Isolation Solenoid Valve
Abnormality (DTC 45) . . . . . . . . . . . . . . . . . 5A–32
Tech 2 Scan Tool . . . . . . . . . . . . . . . . . . . . . . 5A–8
Chart B-15 Rear Dump Solenoid Valve
Getting Started . . . . . . . . . . . . . . . . . . . . . . . . 5A–9 Abnormality (DTC 46) . . . . . . . . . . . . . . . . . 5A–33
Operating Procedure . . . . . . . . . . . . . . . . . . . 5A–9 Chart B-16 FL Speed Sensor Disconnection
Data List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–11 (DTC 51) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–33
EHCU Connector Pin-out Checks . . . . . . . . . 5A–12 Chart B-17 FR Speed Sensor Disconnection
(DTC 52) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–34
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . 5A–13 Chart B-18 RL Speed Sensor Disconnection
Connector List . . . . . . . . . . . . . . . . . . . . . . . . 5A–16 (DTC 53) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–34
Part Location . . . . . . . . . . . . . . . . . . . . . . . . . 5A–18 Chart B-19 RR Speed Sensor Disconnection
Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . 5A–19 (DTC 54) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–35
Chart A–1 ABS Works Frequently But Chart B-20 FL Speed Sensor Short Circuit
Vehicle Does Not Decelerate . . . . . . . . . . . 5A–19 (DTC 61) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–36
Chart TA-1 ABS Works Frequently But Chart B-21 FR Speed Sensor Short Circuit
Vehicle Does Not Decelerate (DTC 62) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–37
(Use TECH 2) . . . . . . . . . . . . . . . . . . . . . . . . 5A–20 Chart B-22 RL Speed Sensor Short Circuit
Chart A-2 Uneven Braking Occurs While (DTC 63) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–38
ABS Works . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–20 Chart B-23 RR Speed Sensor Short Circuit
Chart A-3, TA-3 The Wheels Are Locked . 5A–21 (DTC 64) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–39
Chart A-4 Brake Pedal Feed Is Abnormal . 5A–21 Chart B-24 Sensor Signal Input Abnormality
Chart A-5,TA-5 Braking Sound (DTC 65) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–40
(From EHCU) Is Heard While Not Braking 5A–22 Sensor Signal Abnormality Criteria using
Diagnostic Trouble Codes . . . . . . . . . . . . . . . . 5A–23 TECH 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–40
Diagnosis By “ABS” Warning Light Unit Inspection Procedure . . . . . . . . . . . . . . . . 5A–41
Illumination Pattern . . . . . . . . . . . . . . . . . . . . . 5A–24
5A–2 BRAKE CONTROL SYSTEM
Chart C-1-1 FL Sensor Output Inspection Chart TC-1 Sensor Output Inspection
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–41 Procedure (Use TECH 2) . . . . . . . . . . . . . . 5A–43
Chart C-1-2 FR Sensor Output Inspection Chart C-2 Transmission Input Inspection
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–42 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–44
Chart C-1-3 RL Sensor Output Inspection Chart TC-2 Transmission Input Inspection
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–42 Procedure (Use TECH 2) . . . . . . . . . . . . . . 5A–44
Chart C-1-4 RR Sensor Output Inspection Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–46
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A–43
Service Precaution
systems.
General Description
The Anti-lock Brake System (ABS) works on all four This system helps the driver maintain greater control of
wheels. A combination of wheel speed sensor and the vehicle under heavy braking conditions.
Electronic Hydraulic Control Unit (EHCU) can determine
when a wheel is about to stop turning and adjust brake
pressure to maintain best braking.
C05RW002
Legend (4) Front Wheel Speed Sensor

(1) Electronic (5) Rear Wheel Speed Sensor
(2) Hydraulic (6) G-Sensor
(3) Electronic Hydraulic Control Unit (EHCU) (7) Proportioning and Bypass (P&B) Valve
System Components The EHCU is mounted on the engine compartment front

Electronic Hydraulic Control Unit (EHCU), four Wheel right side. It consists of a Motor, Plunger Pump, Solenoid
Speed Sensors, Warning Light, and G-sensor. Valves and Check Valve.
On the outside, the relay box containing a motor relay and
Electronic Hydraulic Control Unit (EHCU) a valve relay is installed.
Solenoid Valves: Reduces or holds the caliper fluid
The EHCU consists of ABS control circuits, fault detector,
pressure for each front disc brake or both rear disc brakes
and a fail-safe. It drives the hydraulic unit according to the
according to the signal sent from the EHCU.
signal from each sensor, cancelling ABS to return to
Reservoir: Temporarily holds the brake fluid that returns
normal braking when a malfunction has occurred in the
from the front and rear disc brake caliper so that pressure
ABS.
of front disc brake caliper can be reduced smoothly.
The EHCU has a self-diagnosing function which can
Plunger Pump: Feeds the brake fluid held in the reservoir
indicate faulty circuits during diagnosis.
to the master cylinder.
Motor: Drives the pump according to the signal from The G-sensor judges whether the friction coefficient of
EHCU. road surface is low or high, and changes the EHCU’s
Check Valve: Controls the brake fluid flow. operating system to ensure ABS control.
ABS Warning Light Normal and Anti-lock Braking

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

Vehicles equipped with the Anti-lock Brake System may
be stopped by applying normal force to the brake pedal.
821RW033 Although there is no need to push the pedal beyond the
Vehicles equipped with the Anti-lock Brake System have point where it stops or holds the vehicle, by applying more
an amber “ABS” warning light in the instrument panel. force the pedal will continue to travel toward the floor.
The “ABS” warning light will illuminate if a malfunction in This extra brake pedal travel is normal.
the Anti-lock Brake System is detected by the Electronic
Hydraulic Control Unit (EHCU). In case of an electronic Acronyms and Abbreviations
malfunction, the EHCU will turn “ON” the “ABS” warning Several acronyms and abbreviations are commonly used
light and disable the Anti-lock braking function. throughout this section:
The “ABS” light will turn “ON” for approximately three
seconds after the ignition switch is to the “ON” position. ABS
If the “ABS” light stays “ON” after the ignition switch is the Anti-lock Brake System
“ON” position, or comes “ON” and stays “ON” while CKT
driving, the Anti-lock Brake System should be inspected Circuit
for a malfunction according to the diagnosis procedure.
DLC
Wheel Speed Sensor Data Link Connector
It consists of a sensor and a rotor. The sensor is attached EHCU
to the knuckle on the front wheels and to the axle shaft Electronic Hydraulic Control Unit
bearing holder on the rear wheels. FL
The rotor is press-fit in the axle shaft. Front Left
The flux generated from electrodes magnetized by a
magnet in the sensor varies due to rotation of the rotor, FR
Front Right
and the electromagnetic induction generates alternating
voltage in the coil. This voltage draws a “sine curve” with GEN
the frequency proportional to rotor speed and it allows Generator
detection of wheel speed. MV
Millivolts
G-Sensor
The G-sensor installed inside the center console detects RL
the vehicle deceleration speed and sends a signal to the Rear Left
EHCU. In 4WD operation, all four wheels may be RR
decelerated in almost the same phase, since all wheels Rear Right
are connected mechanically.
RPS
This tendency is noticeable particularly on roads with low
Revolution per Second
friction coefficient, and the ABS control is adversely
affected. VDC
Volts DC
VAC D If welding work is to be performed on the vehicle using
Volts AC an electric arc welder, the EHCU and valve block
connectors should be disconnected before the
W/L
welding operation begins.
Warning Light
D The EHCU and valve block connectors should never
WSS be connected or disconnected with the ignition “ON” .
Wheel Speed Sensor
D EHCU of the Anti-lock Brake System are not
separately serviceable and must be replaced as
General Diagnosis assemblies. Do not disassemble any component
which is designated as non-serviceable in this
General Information Section.
ABS malfunction can be classified into two types, those D If only rear wheels are rotated using jacks or drum
which can be detected by the ABS warning light and those tester, the system will diagnose a speed sensor
which can be detected as a vehicle abnormality by the malfunction and the “ABS” warning light will
driver. illuminate. But actually no trouble exists. After
In either case, locate the fault in accordance with the inspection stop the engine once and re-start it, then
“BASIC DIAGNOSTIC FLOWCHART” and repair. make sure that the “ABS” warning light does not
Please refer to Section 5C for the diagnosis of illuminate.
mechanical troubles such as brake noise, brake judder If the battery has been discharged
(brake pedal or vehicle vibration felt when braking),
uneven braking, and parking brake trouble. The engine may stall if the battery has been completely
discharged and the engine is started via jumper cables.
ABS Service Precautions This is because the Anti-lock Brake System (ABS)
requires a large quantity of electricity. In this case, wait
Required Tools and Items: until the battery is recharged, or set the ABS to a
D Box Wrench non-operative state by removing the fuse for the ABS
D Brake Fluid (40A). After the battery has been recharged, stop the
D Special Tool engine and install the ABS fuse. Start the engine again,
and confirm that the ABS warning light does not light.
Some diagnosis procedures in this section require the
installation of a special tool.
Note on Intermittents
J-39200 High Impedance Multimeter
As with virtually any electronic system, it is difficult to
When circuit measurements are requested, use a circuit identify an intermittent failure. In such a case duplicating
tester with high impedance. the system malfunction during a test drive or a good
description of vehicle behavior from the customer may be
Computer System Service Precautions
helpful in locating a “most likely” failed component or
The Anti-lock Brake System interfaces directly with the circuit. The symptom diagnosis chart may also be useful
Electronic Hydraulic Control Unit (EHCU) which is a in isolating the failure. Most intermittent problems are
control computer that is similar in some regards to the caused by faulty electrical connections or wiring. When
Powertrain Control Module. These modules are designed an intermittent failure is encountered, check suspect
to withstand normal current draws associated with circuits for:
vehicle operation. However, care must be taken to avoid
D Suspected harness damage.
overloading any of the EHCU circuits. In testing for opens
or shorts, do not ground or apply voltage to any of the D Poor mating of connector halves or terminals not fully
circuits unless instructed to do so by the appropriate seated in the connector body (backed out).
diagnostic procedure. These circuits should only be D Improperly formed or damaged terminals.
tested with a high impedance multimeter (J-39200) or
special tools as described in this section. Power should Test Driving ABS Complaint Vehicles
never be removed or applied to any control module with In case that there has been an malfunction in the lighting
the ignition in the “ON” position. pattern of “ABS” warning light, the fault can be located in
Before removing or connecting battery cables, fuses or accordance with the “DIAGNOSIS BY “ABS” WARNING
connectors, always turn the ignition switch to the “OFF” LIGHT ILLUMINATION PATTERN” . In case of such
position. trouble as can be detected by the driver as a vehicle
symptom, however, it is necessary to give a test drive
General Service Precautions following the test procedure mentioned below, thereby
The following are general precautions which should be reproducing the symptom for trouble diagnosis on a
observed when servicing and diagnosing the Anti-lock symptom basis:
Brake System and/or other vehicle systems. Failure to 1. Start the engine and make sure that the “ABS” W/L
observe these precautions may result in Anti-lock Brake goes OFF. If the W/L remains ON, it means that the
System damage. Diagnostic Trouble Code (DTC) is stored. Therefore,
read the code and locate the fault.
2. Start the vehicle and accelerate to about 30 km/h (19
mph) or more.
3. Slowly brake and stop the vehicle completely. to the trouble is stored in the EHCU. Only the ordinary
4. Then restart the vehicle and accelerate to about 40 brake system is available when the ABS is turned off.
km/h (25 mph) or more. When the “ABS” warning light is actuated, if the starter
5. Brake at a time so as to actuate the ABS and stop the switch is set ON after setting it OFF once, the EHCU
vehicle. checks up on the entire system and, if there is no
abnormality, judges ABS to work currently and the
6. Be cautious of abnormality during the test. If the W/L
warning light works normally even though the trouble
is actuated while driving, read the DTC and locate the
code is stored.
fault.
7. If the abnormality is not reproduced by the test, make NOTE: Illumination of the “ABS” warning light indicates
best efforts to reproduce the situation reported by the that anti-lock braking is no longer available. Power
customer. assisted braking without anti-lock control is still available.
8. If the abnormality has been detected, repair in
accordance with the “SYMPTOM DIAGNOSIS” . Normal Operation
NOTE: “ABS” Warning Light
D Be sure to give a test drive on a wide, even road with When the ignition is first moved from “OFF” to “ON” , the
little traffic. amber “ABS” warning light will turn “ON” . The “ABS”
warning light will turn “ON” during engine starting and will
D If an abnormality is detected, be sure to suspend the usually stay “ON” for approximately three seconds after
test and start trouble diagnosis at once. the ignition switch is returned to the “ON” position. The
warning light should remain “OFF” at all other times.
“ABS” Warning Light
When ABS trouble occurs and actuates when possible
the “ABS” warning light, the trouble code corresponding
Basic Diagnostic Flow Chart

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

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

Step Action Yes No
1 Turn the key switch on and shift to 4WD position by pressing the
4WD switch. Repair.
Does the 4WD light come on? Go to Step 2 Go to Step 2
2 Reconnect all components and ensure all components are
properly mounted.
3. Ground Inspection
Step Action Yes No
1 Are ABS—related ground points ok? Repair.

properly mounted.
Tech 2 Scan Tool
tool user guide.
901RW257
Legend (3) DLC Cable

(1) PCMCIA Card (4) Tech–2
Getting Started Operating Procedure
D Before operating the Isuzu PCMCIA card with the The power up screen is displayed when you power up the
Tech 2, the following steps must be performed: tester with the Isuzu systems PCMCIA card. Follow the
1. The Isuzu 98 System PCMCIA card (1) inserts into operating procedure below.
the Tech 2 (4).
(3).
3. Connect the DLC cable to the Tech 2 (4).
4. Make sure the vehicle ignition is off.
DLC connector.
821RW021

7. Power up the Tech 2.
060RX065
060RW009
060RX064
Data List
Display Content OK/NG Criteria for Data
Battery Voltage Voltage Between 10–16.9V
Brake Light Switch Open/Close Open(0V) when pedal is released
Closed(12V) when pedal is depressed.
Front Left Wheel Speed MPH(km/h) Start the vehicle and make sure of linear change in each
Front Right Wheel Speed wheel speed.
R
Rear Left
L ft Wheel
Wh l Speed
S d Turn each wheel by hand and make sure that each speed
Rear Left Wheel Speed data change.
Wheel Sensor Status OK/NG To be OK usually
G–sensor Low/High To be Low usually
Transfer Monitor(TOD) 2 Wheel Drive When 2WD: 2 Wheel Drive
4 Wheel Drive When 4WD: 4 Wheel Drive
Off–Road Switch Active/Inactive When shift lever position is 1, 2 and R : Active (M/T)
(Transmission Input)
When shift lever position is L and R : Active (A/T)
Valve Relay Active/Inactive To be Active usually
ABS State ON/OFF To be OFF usually
ABS Relay Active/Inactive To be Active usually
Return Pump Relay Active/Inactive To be Inactive usually
Front Left Isolation Valve Active/Inactive To be Inactive usually
Front Left Dump Valve
Front Right Isolation Valve
Front Right Dump Valve
Rear Isolation Valve
Rear Dump Valve
ABS Warning Lamp ON/OFF To be ON usually (while engine stopped)
EHCU Connector Pin-out Checks

D Disconnect Electronic Brake Control Module.
D Perform checks with high impedance digital
multimeter J-39200 or equivalent.
No. Circuit to be Tested Ignition Multimeter Measure be- Nominal Value Note
Switch Scale/Range tween Pin
Position Number
1 Ignition enable OFF 20DCV 8 (+), 15 (–) 0V to 0.1V
ON 20DCV 8 (+), 15 (–) 11.5V to 14.5V
2 Stop light switch OFF 20DCV 10, 15 10.5V to 14.5V Press brake pedal
3 Ground connection OFF 200W 12, Ground Less than 2W
15, Ground
4 FL speed sensor OFF 2kW 20, 21 1.3k to 1.9kW Internal Resistance
OFF 200kW 20, 15 more than Insulation Resistance
100kW
OFF 200mACV 20, 21 more than Turn wheel at 1RPS
200mV
5 FR speed sensor OFF 2kW 4, 5 1.3k to 1.9kW Internal Resistance
100kW
200mV
6 RL speed sensor OFF 2kW 22, 23 1.3k to 1.9kW Insulation Resistance
OFF 200kW 22, 15 more than Internal Resistance
100kW
200mV
7 RR speed sensor OFF 2kW 2, 3 1.3k to 1.9kW Internal Resistance
100kW
200mV
8 G-sensor ON 26, 8 1k to 2kW Horizontal vehicle
9 Transmission Input ON 20DCV 6 (+), 15 (–) Less than 6V A/T
(shift lever posi- Battery voltage 12V
tion – L, R)
6.6 to 9.0V
(other shift
position)
More than 9.6V M/T
(shift lever posi- Battery voltage 12V
tion – 1, 2, R)
6.6 to 9.0V
(other shift
position)
Circuit Diagram
D08RW033
D08RW034
D08RW035
Connector List
D05RW002
D05RW003
Part Location
D08RW369
Legend (12) C–41

(1) F–2 (13) H–41, H–42
(2) F–3 (14) C–4
(3) I–9 (15) C–85
(4) C–63 (16) Relay & Fuse Box (X–15)
(5) H–7, H–8, H–24, H–25 (17) H–12, H–15, H–16
(6) B–25 (18) C–39
(7) C–16 (19) M–1
(8) Fuse Box (20) M–8
(9) B–13 or B–14 (21) H–33
(10) C–13 (22) I–10
(11) H–10, H–11
Symptom Diagnosis 4. Brake pedal feel is abnormal.

5. Braking sound (from EHCU) is heard while not
The symptoms that cannot be indicated by the warning
braking.
light can be divided in the following five categories:
These are all attributable to problems which cannot be de-
1. ABS works frequently but vehicle does not
tected by EHCU self-diagnosis. Use the customer com-
decelerate.
plaint and a test to determine which symptom is present.
2. Uneven braking occurs while ABS works. Then follow the appropriate flow chart listed below.
3. The wheels lock during braking.
Diagnostic Flow Charts
No
No. Symptom
Sym tom
Without TECH 2 With TECH 2
1 ABS works frequently but vehicle does not decelerate. Chart A–1 Chart TA–1
2 Uneven braking occurs while ABS works. Chart A–2 —
3 The wheels are locked. Chart A–3 Chart TA–3
4 Brake pedal feel is abnormal. Chart A–4 —
5 Braking sound (from EHCU) is heard while not braking. Chart A–5 Chart TA–5
Chart A–1 ABS Works Frequently But Vehicle Does Not Decelerate
Step Action Yes No
1 1. Turn key off.
2. G Sensor connector and EHCU connector disconnected.
Is there continuity between EHCU terminals 26 and 8? Go to Step 2 Go to Step 3
2 Connect EHCU connector. Repair circuit.
Is there continuity between the G sensor and the EHCU? Go to Step 3 Go to Step 1
3 Is the G sensor normal? (Refer to chart B-5) Replace G
sensor.
4 Is braking force distribution normal between the front and rear of Repair brake
the vehicle? parts.
5 Are axle parts installed normally? Go to Step 6 Repair axle parts.
Go to Step 11
6 Is there play in each wheel speed sensor? Repair wheel
speed sensor.
7 Is there damage, or powered iron sticking to each wheel speed Replace sensor
sensor/sensor ring? or sensor ring.
8 Is the output of each wheel speed sensor normal? (Refer to chart Replace wheel
C-1 or TC-1) speed sensor or
repair harness.
9 Is the input of transmission normal? (Refer to chart C-2 or TC-2) Replace switch or
repair harness.
Step Action Yes No

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

Step Action Yes No
1 Is there play in each sensor? Repair.
2 Is there damage or powdered iron sticking to each sensor/sensor Repair.
ring? Go to Step 5 Go to Step 3
3 Is the output of each sensor normal? (Refer to chart C-1 or TC-1) Replace sensor
or repair harness.
4 Is brake pipe connecting order correct? Reconnect brake
Replace EHCU. pipe correctly.
Repeat the “Basic
mounted.
diagnostic flow
Chart A-3, TA-3 The Wheels Are Locked
Step Action Yes No
1 Is ABS working? Go to Step 2 Go to Step 6
2 Is vehicle speed under 10 km/h (6mph)? Normal. Go to Step 3
3 Is sensor output normal? (Chart C-1 or TC-1) Replace sensor
or repair harness.
4 Is transmission input normal? (Chart C-2 or TC-2) Replace SW or
repair harness.
5 Is front 4WD controller normal? Replace 4WD
controller or
Replace EHCU. repair harness.
6 Is transmission input normal? (Chart C-2 or TC-2) Replace SW or
repair harness
7 Is front 4WD controller normal? Replace 4WD
controller or
repair harness.
8 Is hydraulic unit grounded properly? Replace EHCU. Correct.
Repeat the “Basic
mounted.
diagnostic flow
Chart A-4 Brake Pedal Feed Is Abnormal

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

6 Is the check harness/connector for suspended disconnection? Hydraulic system
leakage or air
entry (Refer to
servicing
“Leakage or
brake fluid” ) Repair harness.
Repeat the “Basic
properly mounted.
diagnostic flow
Chart A-5,TA-5 Braking Sound (From EHCU) Is Heard While Not Braking
Step Action Yes No
1 Is this the first time the vehicle is being driven after starting the It is self checking
engine? sound.
Normal. Go to Step 2
2 Is vehicle speed under 10 km/h (6 mph)? It is self checking
sound.
Normal. Go to Step 3
3 Check for the following condition:
D At the time of shift down or clutch operation.
D At the time of low m drive (ice or snow road) or rough road drive.
D At the time of high-speed turn.
D At the time of passing curb. ABS may
D At the time of operating electrical equipment switches. sometime be
D At the time of racing the engine (over 5000 rpm). actuated even
when brake pedal
Did it occur under any one condition above? is not applied. Go to Step 4
4 Is there play in each sensor/wheel speed sensor rings? Repair.
5 Damage or powdered iron sticking to each sensor/wheel speed Repair.
sensor ring? Go to Step 6 Go to Step 7
6 Is each sensor output normal?(Refer to chart C-1 or TC-1). Check harness/
connector for
suspected
disconnection.
If no
disconnection is
found, replace
EHCU. Repair.
Repeat the “Basic
mounted.
diagnostic flow

Choose and trace an appropriate flowchart by the
numbers listed below to find fault and repair.
Code Item Diagnosis Chart No.
12 Start Code Normal —
14 EHCU Function Abnormality in input/output, operational and B-2
control circuits
15 Power Voltage Drop B-3
16 CLASS–2 Communication Line Ab- B-4
normality
21 G-sensor Wiring disconnection B-5
23 Transmission Input Input abnormality B-6
24 Transfer Monitor B-7
32 Motor & Motor Relay Shorted or disconnected coil B-8
35 Valve Relay Shorted or disconnected coil/wiring B-9
41 FL Holding Solenoid Valve Shorted or disconnected coil/wiring B-10
42 FL Decompression Solenoid Valve Shorted or disconnected coil/wiring B-11
43 FR Holding Solenoid Valve Shorted or disconnected coil/wiring B-12
44 FR Decompression Solenoid Valve Shorted or disconnected coil/wiring B-13
45 Rear Holding Solenoid Valve Shorted or disconnected coil/wiring B-14
46 Rear Decompression Solenoid Valve Shorted or disconnected coil/wiring B-15
51 FL Wheel Speed Sensor Disconnected coil/wiring B-16
52 FR Wheel Speed Sensor Disconnected coil/wiring B-17
53 RL Wheel Speed Sensor Disconnected coil/wiring B-18
54 RR Wheel Speed Sensor Disconnected coil/wiring B-19
61 FL Wheel Speed Sensor Shorted coil/wiring B-20
62 FR Wheel Speed Sensor Shorted coil/wiring B-21
63 RL Wheel Speed Sensor Shorted coil/wiring B-22
64 RR Wheel Speed Sensor Shorted coil/wiring B-23
65 Sensor Signal Input Wrong number of teeth B-24
Diagnosis By “ABS” Warning Light or if the warning light is actuated during driving, trouble
should be diagnosed on a illumination pattern basis as
Illumination Pattern follows:
In the event that there is abnormality in the “ABS” warning
light illumination pattern while the key is in the ON position
No. Condition “ABS” Warning Light Illumination Pattern Diagnostic
1 Warning light is actu- Normal
ated normally
2 Warning light is not lit Warning light lighting circuit

trouble→Go to Chart B-1
3 Warning light remains Diagnostic trouble codes are

ON stored.
Display diagnostic trouble
codes and diagnose on a
code basis according to the
flow charts.
4 Warning light is actu- Diagnostic trouble codes are

ated while driving stored.
Display diagnostic trouble
codes and diagnose on a
code basis according to the
flow charts.
Diagnostic Trouble Codes (DTCs) D DTCs can be displayed also by TECH 2. Select mode
When the warning light in the meter remains ON, the “F0: Diagnostic Trouble Codes” from Application
Menu.
EHCU stores the fault identification and disables the
ABS. 1. How to start DTC display:
1. How to display and erase DTCs: D Confirm that the vehicle has come to a complete
stop (with the wheels standing still) and that the
NOTE: brake pedal is not depressed. (Unless these two
D If DTCs are not displayed, harness C-4 connector conditions are satisfied, DTC display cannot be
terminal 30 and I-10 connector terminal 2 may be started.)
disconnected. Repair the harness and try DTC D With IGN OFF, connect #12 terminal with #4
display again. terminal or # 5 terminal (GND) . Then turn IGN ON.
The DLC is located behind the driver side kick panel
350RT001
D Keep #12 terminal connected with #4 terminal or # 5

terminal (GND) during DTC display. (If #12 terminal
is separated from #4 terminal or # 5 terminal (GND)
during display, display will stop.)
2. DTC display:
D DTC is displayed by blinking warning light.
D Double-digit display.
D First, normal DTC 12 is displayed three times and
then any other DTCs are displayed three times. (If
no other DTCs have been stored, the display of DTC
12 will be repeated.)
3. How to erase code:
D Conduct brake switch ON/OFF operation 6 or more
times within 3 seconds of self-diagnosis startup.
D The code cannot be erased if more than 3 seconds
have passed since self-diagnosis startup, or if
self-diagnosis has started with brake switched on
(brake pedal depressed).
B05RW005
4. Notes
D If the following should occurs during Diagnostic
Trouble Code (DTC) display the display will be
discontinued. After initial check, the status that is
under the control of ABS will be returned :
– The vehicle starts (The wheels turn) or the brake
pedal is depressed.
D Up to 3 different codes can be stored.
D If the ABS should turn OFF due to an intermittent
defect, the system will be restored at the next key
cycle, if the initial check finds no abnormality (when
IGN is switched from OFF to ON).
5. An example of DTC display
Display of DTC 23
B05RW006
After displaying DTC 12 three times, one DTC after

another is displayed, starting with the most recent
one. (However, display is discontinued after about 5
minutes.)
B05RS005
The DTC 12 is displayed repeatedly. (display is

discontinued after about 5 minutes)
Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L)
is not activated.
Step Action Yes No
1 Is W/L fuse C-10 disconnected? Replace fuse.
2 Is W/L burnt out? Replace W/L
bulb.
3 1. Turn the key off.
2. Disconnect EHCU connector.
3. Turn the key ON.
4. Measure the voltage between EHCU connector terminal 16 Repair harness
and 15. and connector.
Is the voltage equal to the battery voltage? Go to Step 4 Go to Step 5
4 Is there continuity between EHCU connector terminals, 12 and 15 Check harness
and body ground. for suspected
disconnection.
No fault found: Repair harness
Replace EHCU. and connector.
Repeat the “Basic
mounted.
diagnostic flow
Chart B-2 EHCU Abnormality (DTC 14)

Step Action Yes No
2. Disconnect the EHCU connector.
3. Inspect EHCU ground. Repair the body
Is there resistance between the EHCU connector terminals, 12 ground harness.
and 15 and body ground? Go to Step 2 Go to Step 3
2 1. Turn the key off, connect the EHCU.
2. Erase the trouble code.
Inspect in
3. Turn Ignition off, then on, to perform system self-check.
accordance with
4. If warning light remains on, display trouble codes once again. Replace EHCU. the DTC
Is the check trouble code 14? Go to Step 3 displayed.
3 1. Reconnect all components and ensure all components are
properly mounted.
Repeat the “Basic
diagnostic flow
Chart B-3 Power Voltage Drop (DTC 15)
Step Action Yes No
1 Is the battery voltage normal? (Battery capacity check) Charge or
replace battery.
2 1. Turn the key off. Check harness
2. Disconnect EHCU connector. connector for
3. Turn the key on. suspected
disconnection.
Is the voltage between EHCU connector terminals 8 and 15,
higher than 10V? Fault found:
Repair, and
perform system
self-check.
No fault found: Repair harness or
replace EHCU. connector.
3 1. Reconnect all components, ensure all components are
properly mounted.
Repeat the “Basic
diagnostic flow
Chart B-4 CLASS-2 Communication Line Abnormality (DTC 16)

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

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

3 Remove G sensor. Replace G
Is the resistance between the G sensor connector terminals 1 and sensor.
2 within 1.0-2.0 kW when G sensor is horizontal? Go to Step 4 Go to Step 5
4 Measure resistance between G sensor connector terminals 1 and Harness between
2 within 4.0-6.0 kW when G sensor tilted to 30° or more? EHCU and G
sensor is faulty
and short.
Repair the Replace G
harness sensor.
properly mounted.
Repeat the “Basic
diagnostic flow
Chart B-6 Abnormal Transmission Input (DTC 23)

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

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

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

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

Step Action Yes No
Connector
connector.
Repeat the “Basic
Diagnostic Flow
Repeat the “Basic
mounted.
Diagnostic Flow
Chart B-12 FR Isolation Solenoid Valve Abnormality (DTC 43)
Step Action Yes No
Connector
connector.
Repeat the “Basic
Diagnostic Flow
Repeat the “Basic
mounted.
Diagnostic Flow
Chart B-13 FR Dump Solenoid Valve Abnormality (DTC 44)

Step Action Yes No
Connector
connector.
Repeat the “Basic
Diagnostic Flow
Repeat the “Basic
mounted.
Diagnostic Flow
Chart B-14 Rear Isolation Solenoid Valve Abnormality (DTC 45)

Step Action Yes No
Connector
connector.
Repeat the “Basic
Diagnostic Flow
Repeat the “Basic
mounted.
Diagnostic Flow
Chart B-15 Rear Dump Solenoid Valve Abnormality (DTC 46)
Step Action Yes No
Connector
connector.
Repeat the “Basic
Diagnostic Flow
Repeat the “Basic
mounted.
Diagnostic Flow
Chart B-16 FL Speed Sensor Disconnection (DTC 51)

Step Action Yes No
1 1. Turn the key off. Check for faults
2. Disconnect EHCU connector. in harness
3. Measure the resistance between EHCU connector terminals between speed
20 and 21. sensor and
EHCU.
Is the resistance between 1.3k and 1.9k ohms?
Fault found:
Repair, and
perform system
self-check.
No fault found:
Replace EHCU.
2 Measure the FL speed sensor resistance at the sensor connector. Repair harness
abnormality
between sensors
and EHCU. Replace sensor.
properly mounted.
Repeat the “Basic
diagnostic flow
Chart B-17 FR Speed Sensor Disconnection (DTC 52)
Step Action Yes No
3. Measure the resistance between EHCU connector terminals 4 between speed
and 5. sensor and
EHCU.
Fault found:
Repair, and
perform system
self-check.
No fault found:
Replace EHCU.
2 Measure the FR speed sensor resistance at the sensor Repair harness
connector. abnormality
between sensors
properly mounted.
Repeat the “Basic
diagnostic flow
Chart B-18 RL Speed Sensor Disconnection (DTC 53)

Step Action Yes No
3. Measure the resistance between EHCU connector terminals between speed
22 and 23. sensor and
EHCU.
Fault found:
Repair, and
perform system
self-check.
No fault found:
Replace EHCU.
2 Measure the RL speed sensor resistance at the sensor Repair harness
between sensors
properly mounted.
Repeat the “Basic
diagnostic flow
Chart B-19 RR Speed Sensor Disconnection (DTC 54)
Step Action Yes No
3. Measure the resistance between EHCU connector terminals 2 between speed
and 3. sensor and
EHCU.
Is the resistance between 1.3K and 1.9k ohms?
Fault found:
Repair, and
perform system
self-check.
No fault found:
Replace EHCU.
Go to Step 3. Go to Step 2
2 Measure the RR speed sensor resistance at the sensor Repair harness
between sensors
Is the sensor resistance between 1.3k and 1.9k ohms?
and EHUC. Replace sensor.
properly mounted.
Repeat the “Basic
diagnostic flow
Chart B-20 FL Speed Sensor Short Circuit (DTC 61)
Step Action Yes No
2. Disconnect EHCU connector
3. Measure the FL speed sensor resistance between EHCU
connector terminals 20 and 21.
Is the resistance between 1.3k and 1.9k ohms? Go to Step 2 Go to Step 3
2 Is there play in the sensor/sensor rotor? Repair.
3 Measure the FL speed sensor resistance at the sensor connector. Repair harness
abnormality
between sensors
4 Damage and powdered iron sticking to sensor/sensor ring? Repair.
5 Is sensor output normal? (Chart C-2 or TC-2) Check for faults
in harness
between speed
sensor and
EHCU.
Fault found:
repair, and
perform system
self-check.
No fault found:
replace EHCU. Replace sensor.
properly mounted.
Repeat the “Basic
diagnostic flow
NOTE: Even after repairing the faulty part the warning
light (W/L) does not go out if the vehicle is at a stop. Turn
the ignition switch to the ON position and drive the vehicle
at 12 km/h or higher to make sure that the warning light
goes out.
Chart B-21 FR Speed Sensor Short Circuit (DTC 62)
Step Action Yes No
3. Measure the FR speed sensor resistance between EHCU
3 Measure the FR speed sensor resistance at the sensor Repair harness
between sensors
in harness
between speed
sensor and
EHCU.
Fault found:
repair, and
perform system
self-check.
No fault found:
properly mounted.
Repeat “Basic
diagnostic flow
goes out.
Chart B-22 RL Speed Sensor Short Circuit (DTC 63)
Step Action Yes No
2. Disconnect EHCU connector
3. Measure the RL speed sensor resistance between EHCU
3 Measure the RL speed sensor resistance at the sensor Repair harness
between sensors
5 Is sensor output normal? (Chart C-2 or TC-2)? Check for faults
in harness
between speed
sensor and
EHCU.
Fault found:
repair, and
perform system
self-check.
No fault found:
properly mounted.
Repeat the “Basic
diagnostic flow
goes out.
Chart B-23 RR Speed Sensor Short Circuit (DTC 64)
Step Action Yes No
3. Measure the RR speed sensor resistance between EHCU
3 Measure the RR speed sensor resistance at the sensor Repair harness
between sensors
in harness
between speed
sensor and
EHCU.
Fault found:
repair, and
perform system
self-check.
No fault found:
properly mounted.
Repeat “Basic
diagnostic flow
goes out.
Chart B-24 Sensor Signal Input Abnormality (DTC 65)
Step Action Yes No
1 Using TECH 2? Go to Step 2 Go to Step 3
2. Select Snap shot manual trigger. Go to Step 3
3. With wheel speed data displayed, run the vehicle when speed
All the sensors
has arrived at 30 km/h (18 mph).
should follow the
4. Check speed data on each wheel (refer to the criterion given
following
below). *1 Replace. flowchart (without
Is the abnormal sensor condition found? Go to Step 8 using TECH 2).
3 Is there play in sensor/sensor ring? Repair.
4 Is there powdered iron sticking to sensor/sensor ring? Repair.
5 Is there a broken tooth or indentation in sensor ring? Replace sensor
ring.
6 Is there play in wheel bearing? Adjust or repair.
7 Is the check wiring between sensor and EHCU normal? Repair, and
perform system
Replace EHCU. self-check.
properly mounted.
Repeat “Basic
diagnostic flow
Sensor Signal Abnormality Criteria using

TECH 2
1. While driving, the speed of one or two wheels 25% or
more higher than that of the other wheels.
2. The speed of one or two wheels is 10 km/h (6 mph) or
more higher than that of the other wheels.
3. During steady driving, wheel speed changes abruptly.
*1 The vehicle must run on a level paved road.
light (W/L) does not go out if the vehicle is at a stop.
Turn the ignition switch to the ON position and drive the
vehicle at 12 km/h or higher to make sure that the warning
light goes out.
It is important to verify that the correct tires are installed
on vehicle.
Unit Inspection Procedure “DIAGNOSIS BY ‘ABS’ WARNING LIGHT ILLUMINA-

TION PATTERN” :
This section describes the following inspection proce-
dures referred to during “SYMPTOM DIAGNOSIS” and
without TECH 2 with TECH 2
Wheel Speed Sensor Output Inspection Chart C-1-1 to C-1-4 Chart TC-1
Transmission SW Inspection Chart C-2 Chart TC-2
Chart C-1-1 FL Sensor Output Inspection Procedure

Step Action Yes No
3. Jack up the vehicle, With all four wheels off the ground.
Measure the AC voltage between EHCU connector terminals
while turning FL wheel at a speed of 1 RPS:
Is voltage between EHCU connector terminals 20 and 21 under Ok.
200 mV? Go to Step 2 Go to Step 3
2 1. Disconnect the wheel speed sensor. Connector is
2. Measure resistance between the wheel speed sensor faulty, or open or
connector terminals 1 and 2. short circuit in
harness between
Is resistance between connector (C-13) terminals 1 and 2 within
wheel speed
1.3k - 1.9k ohms?
sensor connector
and EHCU. Wheel speed
Inspect and sensor is faulty.
correct the Replace the
connector or wheel speed
harness sensor.
Repeat the “Basic
properly mounted.
diagnostic flow
Chart C-1-2 FR Sensor Output Inspection Procedure
Step Action Yes No
3. Jack up the vehicle with all four wheels off the ground.
while turning FR wheel at a speed of 1 RPS:
Is voltage between EHCU connector terminals 4 and 5 under 200 Ok.
mV? Go to Step 2 Go to Step 3
connector terminals 1 and 2. short circuit of
harness between
Is resistance between connector (C-41) terminals 1 and 2 within
wheel speed
1.3k - 1.9k ohms?
sensor connector
harness sensor.
Repeat the “Basic
properly mounted.
diagnostic flow
Chart C-1-3 RL Sensor Output Inspection Procedure

Step Action Yes No
while turning RL wheel at a speed of 1 RPS:
Is voltage between EHCU connector terminals 22 and 23 under Ok.
200 mV? Go to Step 2 Go to Step 3
harness between
Is resistance between connector (F-3) terminals 1 and 2 within
wheel speed
1.3k - 1.9k ohms?
sensor connector
harness sensor.
Repeat the “Basic
properly mounted.
diagnostic flow
Chart C-1-4 RR Sensor Output Inspection Procedure
Step Action Yes No
while turning RR wheel at a speed of 1 RPS:
Is voltage between EHCU connector terminals 2 and 3 under 200 Ok.
mV? Go to Step 2 Go to Step 3
harness between
Is resistance between connector (F-2) terminals 1 and 2 within
wheel speed
1.3k - 1.9k ohms?
sensor connector
harness sensor.
Repeat the “Basic
properly mounted.
diagnostic flow
Chart TC-1 Sensor Output Inspection Procedure (Use TECH 2)

Step Action Yes No
2. While driving the vehicle, check the wheel speed of each
sensor by Data List.
Is the vehicle speed value is normal? Go to Step 6 Go to Step 2
2 Check the sensor harness for suspected disconnection (Check Replace speed
while shaking harness/connector). sensor. Repair.
Is the sensor harness connection normal? Go to Step 3 Go to Step 6
3 While driving the vehicle, check the wheel speed of each sensor
by Data List.
Is the vehicle speed value is normal? Go to Step 6 Go to Step 4
4 Check sensor roter. Replace sensor
roter.
Is the sensor roter normal?
5 While driving the vehicle, check the wheel speed of each sensor Repair harness or
by Data List. connector
between EHCU
Is the vehicle speed value is normal?
and speed
sensor.
Repeat the “Basic
mounted.
diagnostic flow
Chart C-2 Transmission Input Inspection Procedure
Step Action Yes No
1 1. Turn the key off. Shorted switch
2. Disconnect EHCU connector. harness.
Is there continuity between EHCU connector terminals 6 and 15 Repair switch or
(Gear position-P(A/T), N(M/T))? harness.
2 Is the vehicle an A/T model? Go to Step 3 Go to Step 4
3 Turn the key on and measure voltage between EHCU connector Transmission SW
terminals 6 and 15. trouble.
Is there less than 6V when the gear position is L, and R(Battery Disconnected
voltage 12V)? harness.
Repair SW and
harness.
Is there more than 9.6V when the gear position is 1, 2, R(Battery Disconnected
voltage 12V)? harness.
Repair SW and
harness.
5 Measure the voltage between EHCU connector terminals 6 and Transmission SW
15. trouble.
Is there 6.6 to 9.0V when the gear position is 3, 4, 5 and N(M/T) or Disconnected
2,3,D,N and P(A/T)(Battery voltage 12V)? harness.
Repair SW and
harness.
properly mounted.
Repeat the “Basic
diagnostic flow
Chart TC-2 Transmission Input Inspection Procedure (Use TECH 2)
Step Action Yes No
2. Select Data List.
Is this vehicle an A/T model ? Go to Step 2 Go to Step 4
2 Is “Off–Road Switch(Transmission Input): Active” when the shift
lever is the L and R? Go to Step 3 Go to Step 6
3 Is “Off–Road Switch(Transmission Input): Inactive” when the shift
lever is other than the L and R? Go to Step 7 Go to Step 6
4 Is “Off–Road Switch(Transmission Input): Active” when the shift
lever is in 1, 2 and R? Go to Step 5 Go to Step 6
5 Is “Off–Road Switch(Transmission Input): Inactive” when the shift
lever is other than the 1, 2 and R? Go to Step 7 Go to Step 6
6 1. Abnormal T/M SW, inhibitor SW, or harness.
2. Repair T/M SW, inhibitor SW, or harness.
Is the T/M SW, inhibitor SW, or harness repaired? Go to Step 7 Go to Step 6
Repeat the “Basic
mounted.
diagnostic flow
Special Tools
TOOL NO.
ILLUSTRATION
TOOL NAME
J–35616
Connector test adapter
kit
J–39200
High impedance
multimeter
7000086–ISU
Tech 2 Set
(1) PCMCIA Card
(2) SAE 16/19 Adapter
(3) DLC Cable
(4) Tech 2
ANTI–LOCK BRAKE SYSTEM 5B–1
TROOPER
BRAKES
ANTI-LOCK BRAKE SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 5B–1 Front Wheel Speed Sensor and
Electronic Hydraulic Control Unit . . . . . . . . . . 5B–2 Associated Parts . . . . . . . . . . . . . . . . . . . . . . 5B–4
Electronic Hydraulic Control Unit and Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B–4
Associated Parts . . . . . . . . . . . . . . . . . . . . . . 5B–2 Inspection and Repair . . . . . . . . . . . . . . . . . . 5B–5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B–2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B–5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B–2 Rear Wheel Speed Sensor . . . . . . . . . . . . . . . 5B–6
G-Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B–3 Rear Wheel Speed Sensor and
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B–3 Associated Parts . . . . . . . . . . . . . . . . . . . . . . 5B–6
Inspection and Repair . . . . . . . . . . . . . . . . . . 5B–3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B–6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B–3 Inspection and Repair . . . . . . . . . . . . . . . . . . 5B–6
Front Wheel Speed Sensor . . . . . . . . . . . . . . . 5B–4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B–6
Service Precaution
systems.
5B–2 ANTI–LOCK BRAKE SYSTEM
Electronic Hydraulic Control Unit

Electronic Hydraulic Control Unit and Associated Parts
350RW013
Legend (3) Bolts

(1) Connector (4) Nut
(2) Hydraulic Unit ASM (5) Bolt
1. Remove battery ASM. To install, follow the removal steps in the reverse order,
2. Remove harness connector.
Torque
3. Remove EHCU fixing nuts.
Hydraulic unit fixing nuts : 22 N·m (16 lb ft)
4. Remove brake pipes.
Ground cable : 14 N·m (10 lb ft)
D After disconnecting brake pipe, cap or tape the
openings of the brake pipe to prevent the entry of Brake pipe (joint bolts) : 16 N·m (12 lb ft)
foreign matter. D After installing the hydraulic unit, bleed brakes
5. Remove hydraulic unit fixing nuts. completely. See Section 5A “Hydraulic Brakes”.
G-Sensor
1. Install G-sensor assembly (3).
D Care should be taken so that the G-sensor is not
installed in the wrong direction.
2. Install G-sensor assembly fixing bolt (2).
D Tighten the fixing bolt to the specified torque.
3. Install G-sensor wiring connector (1).
4. Install center console.
section.
350RX001

section.
2. Remove clip from G-sensor connector, then
disconnect connector.
3. Remove G-sensor assembly fixing bolt (2).
4. Remove G-sensor assembly (3).

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

Front Wheel Speed Sensor and Associated Parts
350RW012
Legend (3) Sensor Cable Fixing Bolt (Lower side)

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

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

tighten the fixing bolt to the specified torque.
4. Install speed sensor cable fixing bolt (Upper side) and
tighten the fixing bolt to the specified torque.
Rear Wheel Speed Sensor

Rear Wheel Speed Sensor and Associated Parts
350RW008
Legend (3) Clip (11 pieces)

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

1. Check the speed sensor pole piece for presence of
foreign materials; remove any dirt, etc.
POWER ASSISTED BRAKE SYSTEM 5C–1
TROOPER
BRAKES
POWER-ASSISTED BRAKE SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 5C–2 Master Cylinder Assembly and
General Description . . . . . . . . . . . . . . . . . . . . . 5C–2 Associated Parts . . . . . . . . . . . . . . . . . . . . . . 5C–21
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–21
General Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 5C–6 Inspection and Repair . . . . . . . . . . . . . . . . . . 5C–21
Hydraulic Brakes . . . . . . . . . . . . . . . . . . . . . . . . 5C–9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–22
Filling Master Cylinder Reservoir . . . . . . . . 5C–9 Main Data and Specifications . . . . . . . . . . . 5C–23
Deterioration of Brake Fluid . . . . . . . . . . . . . 5C–9 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–24
Leakage of Brake Fluid . . . . . . . . . . . . . . . . . 5C–9 Vacuum Booster Assembly . . . . . . . . . . . . . . . 5C–25
Bleeding Brake Hydraulic System . . . . . . . . 5C–9 Vacuum Booster Assembly and
Flushing Brake Hydraulic System . . . . . . . . 5C–10 Associated Parts . . . . . . . . . . . . . . . . . . . . . . 5C–25
Brake Pipes and Hoses . . . . . . . . . . . . . . . . 5C–10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–25
Brake Hose Inspection . . . . . . . . . . . . . . . . . 5C–10 Inspection and Repair . . . . . . . . . . . . . . . . . . 5C–25
Front / Rear Caliper Brake Hose . . . . . . . . . . 5C–11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–26
Front / Rear Caliper Brake Hose and Exterior Components . . . . . . . . . . . . . . . . . . . . 5C–28
Associated Parts . . . . . . . . . . . . . . . . . . . . . . 5C–11 Exterior Components and
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–11 Associated Parts . . . . . . . . . . . . . . . . . . . . . . 5C–28
Rear Axle Brake Hose . . . . . . . . . . . . . . . . . . . 5C–12 Inspection and Repair . . . . . . . . . . . . . . . . . . 5C–29
Rear Axle Brake Hose and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–29
Associated Parts . . . . . . . . . . . . . . . . . . . . . . 5C–12 Vacuum Booster Overhaul . . . . . . . . . . . . . . . . 5C–29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–12 Vacuum Booster . . . . . . . . . . . . . . . . . . . . . . . 5C–29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–12 Main Data and Specifications . . . . . . . . . . . . . 5C–30
Brake Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–13 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–13 Front Disc Brake Pads . . . . . . . . . . . . . . . . . . . 5C–32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–13 Front Disc Brake Pads Inspection . . . . . . . . 5C–32
P & B (Proportioning and Bypass) Valve . . . . 5C–14 Front Disc Brake Pads and
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–14 Associated Parts . . . . . . . . . . . . . . . . . . . . . . 5C–32
Main Data and Specifications . . . . . . . . . . . . . 5C–15 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–33
Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–16 Front Disc Brake Rotor . . . . . . . . . . . . . . . . . . . 5C–35
Checking Pedal Height . . . . . . . . . . . . . . . . . 5C–16 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–35
Checking Pedal Travel . . . . . . . . . . . . . . . . . 5C–16 Replacing Brake Rotors . . . . . . . . . . . . . . . . 5C–35
Brake Pedal and Associated Parts . . . . . . . 5C–17 Refinishing Brake Rotors . . . . . . . . . . . . . . . 5C–35
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–17 Front Disc Brake Caliper Assembly . . . . . . . . 5C–37
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–17 Front Disc Brake Caliper Assembly
Stoplight Switch . . . . . . . . . . . . . . . . . . . . . . . . . 5C–18 and Associated Parts . . . . . . . . . . . . . . . . . . 5C–37
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–37
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–18 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–38
Main Data and Specifications . . . . . . . . . . . . . 5C–19 Front Disc Brake Caliper . . . . . . . . . . . . . . . . . 5C–40
Fluid Reservoir Tank . . . . . . . . . . . . . . . . . . . . . 5C–20 Front Disc Brake Caliper Disassembled
View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–40
Fluid Reservoir Tank and Associated Parts 5C–20
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–40
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–20
Inspection and Repair . . . . . . . . . . . . . . . . . . 5C–41
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–20
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–41
Master Cylinder Assembly . . . . . . . . . . . . . . . . 5C–21
Main Data and Specifications . . . . . . . . . . . 5C–43
5C–2 POWER ASSISTED BRAKE SYSTEM
Rear Disc Brake Pads . . . . . . . . . . . . . . . . . . . 5C–44 Rear Disc Brake Caliper Assembly and
Brake Pads Inspection . . . . . . . . . . . . . . . . . 5C–44 Associated Parts . . . . . . . . . . . . . . . . . . . . . . 5C–49
Brake Pads and Associated Parts . . . . . . . 5C–44 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–49
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–45 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–50
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–45 Rear Disc Brake Caliper . . . . . . . . . . . . . . . . . . 5C–52
Rear Disc Brake Rotor . . . . . . . . . . . . . . . . . . . 5C–47 Rear Disc Brake Caliper Disassembled
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–47 View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–52
Replacing Brake Rotors . . . . . . . . . . . . . . . . 5C–47 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–52
Refinishing Brake Rotors . . . . . . . . . . . . . . . 5C–47 Inspection and Repair . . . . . . . . . . . . . . . . . . 5C–53
Rear Drum (In Disc) Inside Diameter Check 5C–48 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 5C–53
Rear Disc Brake Caliper Assembly . . . . . . . . 5C–49 Main Data and Specifications . . . . . . . . . . . 5C–55
Service Precaution General Description

WARNING: THIS VEHICLE HAS A SUPPLEMENTAL Master Cylinder Assembly
systems.
330RW013
The master cylinder contains two pistons that supply the

hydraulic pressure for a dual–circuit braking system. The
primary piston provides the fluid pressure to the front
brakes, while the secondary piston provides the fluid
pressure to the rear brakes. If the pressure is lost from
either system, the remaining system will function to stop
the vehicle.
CAUTION: 3. The torque values specified are for dry,
1. The master cylinder is not repairable. If found un-lubricated fasteners.
defective, it must be replaced as a complete 4. Perform service operations on a clean bench free
assembly. from all mineral oil materials.
2. If any hydraulic component is removed or
disconnected, it may be necessary to bleed all or
part of the brake system. (Refer to “On–Vehicle
Service” in this section.)
Brake Booster
331RS001
This booster is a tandem vacuum unit with a diaphragm Disc Brake

effective diameter 205mm + 230mm. In normal operating The disc brake assembly consists of a caliper, piston,
mode, with the service brakes in the released position, rotor, pad assembly and support bracket. The caliper
the tandem vacuum booster operates with vacuum on assembly has a single bore and is mounted to the support
both sides of its diaphragms. When the brakes are bracket with two mounting bolts. The support bracket
applied, air at atmospheric pressure is admitted to one allows the caliper to move laterally against the rotor. The
side of each diaphragm to provide the power assist. caliper is a one–piece casting with the inboard side
When the service brake is released, the atmospheric air is containing the piston bore. A square cut rubber seal is
shut off from the one side of each diaphragm. The air is located in a groove in the piston bore which provides the
then drawn from the booster through the vacuum check hydraulic seal between the piston and the cylinder wall.
valve to the vacuum source.
NOTE:
CAUTION:
1. Replace all components included in repair kits used to
1. If any hydraulic component is removed or
service this caliper.
disconnected, it may be necessary to bleed all or
part of the brake system. 2. Lubricate rubber parts with clean brake fluid to ease
assembly.
2. The torque values specified are for dry,
unlubricated fasteners. 3. If any hydraulic component is removed or
disconnected, it may be necessary to bleed all or part
3. The vacuum booster is not repairable and must be of the brake system.
replaced as a complete assembly. 4. Replace pads in axle sets only.
5. The torque values specified are for dry, unlubricated 6. Perform the service operation on a clean bench free
fasteners. from all mineral oil materials.
Operation
Front Disc Brake
A05RW001
Rear Disc Brake
A05RW002
Hydraulic pressure, created by applying the brake pedal,

is converted by the caliper to a stopping force. This force
acts equally against the piston and the bottom of the
caliper bore to move the piston outward and to move
(slide) the caliper inward resulting in a clamping action on
the rotor. This clamping action forces the linings against
the rotor, creating friction to stop the vehicle.
Diagnosis 3. Wheel Alignment: Misalignment of the wheels,

particularly in regard to excessive camber and caster,
Road Testing The Brakes will cause the brakes to pull to one side.
Brake Test Brake Fluid Leaks
Brakes should be tested on a dry, clean, reasonably With engine running at idle and the transmission in
smooth and level roadway. A true test of brake “Neutral”, depress the brake pedal and hold a constant
performance cannot be made if the roadway is wet, foot pressure on the pedal. If pedal gradually falls away
greasy or covered with loose dirt so that all tires do not with the constant pressure, the hydraulic system may be
grip the road equally. Testing will also be adversely leaking.
affected if the roadway is crowned so as to throw the Check the master cylinder fluid level. While a slight drop in
weight of the vehicle toward wheels on one side or if the the reservoir level will result from normal lining wear, an
roadway is so rough that wheels tend to bounce. Test the abnormally low level in reservoir indicates a leak in the
brakes at different vehicle speeds with both light and system. The hydraulic system may be leaking internally
heavy pedal pressure; however, avoid locking the wheels as well as externally. Refer to “Master Cylinder
and sliding the tires. Locked wheels and sliding tires do Inspection”. Also, the system may appear to pass this test
not indicate brake efficiency, since heavily braked but but still have slight leakage. If fluid level is normal, check
turning wheels will stop the vehicle in less distance than the vacuum booster push rod length. If an incorrect length
locked wheels. More tire–to–road friction is present with a push rod is found, adjust or replace the push rod. Check
heavily braked turning tire then with a sliding tire. the brake pedal travel and the parking brake adjustment.
The standard brake system is designed and balanced to When checking the fluid level, the master cylinder fluid
avoid locking the wheels except at very high deceleration level may be low from the “MAX” mark if the front and rear
levels. linings are worn. This is not abnormal.
It is designed this way because the shortest stopping
distance and best control is achieved without brake Warning Light Operation
lock–up.
When the ignition switch is in the START position, the
Because of high deceleration capability, a firmer pedal
“BRAKE” warning light should turn on and go off when the
may be felt at higher deceleration levels.
ignition switch returns to the ON position.
External Conditions That Affect Brake Performance The following conditions will turn on the “BRAKE” light:
1. Tires: Tires having unequal contact and grip on the 1. Parking brake applied. The light should be on
road will cause unequal braking. Tires must be whenever the parking brake is applied and the ignition
equally inflated, identical in size, and the thread switch is on.
pattern of right and left tires must be approximately 2. Low fluid level. A low fluid level in the master cylinder
equal. will turn the “BRAKE” light on.
2. Vehicle Loading: A heavily loaded vehicle requires 3. During engine cranking the “BRAKE” light should
more braking effort. remain on. This notifies the driver that the warning
circuit is operating properly.
General Diagnosis
Brake Pull Tire inflation pressure is unequal. Adjust
Front wheel alignment is incorrect. Adjust
Unmatched tires on same axle. Tires with approx. the same amount
of tread should be used on the same
axle.
Restricted brake pipes or hoses. Check for soft hoses and damaged
lines. Replace with new hoses and
new double“walled steel brake
piping.
Water or oil on the brake pads. Clean or replace.
Brake pads hardened. Replace
Brake pads worn excessively. Replace
Brake rotor worn or scored. Grind or replace.
Disc brake caliper malfunctioning. Clean or replace.
Front hub bearing preload incorrect. Adjust or replace.
Loose suspension parts. Check all suspension mountings.
Loose calipers. Check and tighten the bolts to
specifications.
Brake Roughness or Chatter Excessive lateral runout. Check per instructions. If not within
(Pulsates) specifications, replace or machine
the rotor.
Parallelism not within specifications. Check per instructions. If not within
specifications, replace or machine
the rotor.
Wheel bearings not adjusted. Adjust wheel bearings to correct
specifications
Pad reversed (steel against iron). Replace the brake pad and machine
rotor to within specifications.
Excessive Pedal Effort Malfunctioning vacuum booster. Check the vacuum booster operation
and repair, if necessary.
Partial system failure. Check the front and rear brake
system for failure and repair. Also,
check the brake warning light. If a
failed system is found, the light
should indicate failure.
Excessively worn pad. Check and replace pads in sets.
Piston in caliper stuck or sluggish. Remove caliper and rebuild.
Fading brakes due to incorrect pad. Remove and replace with original
equipment pad or equivalent.
Vacuum leak to vacuum booster. Check for ruptured or loose hose.
Check the direction of check valve Correct vacuum hose direction.
within vacuum hose.
Grease on the brake pads. Replace or clean.

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

Poor Brake Action Master cylinder faulty. Correct or replace.
Vacuum booster faulty. Correct or replace.
Level of brake fluid in reservoir too Replenish and bleed.
low.
Air in hydraulic circuit. Bleed
Disc brake caliper faulty. Clean or replace.
Water or oil on brake pads. Clean or replace.
Brake pads in poor contact with the Correct
brake disc.
Brake pads worn. Replace
Brake disc rusted. Grind or replace.
Check valve in vacuum hose faulty. Correct or replace.
Hydraulic Brakes
Filling Master Cylinder Reservoir cylinder and brakes, then the brake system served by the
disconnected pipe must be bled.
CAUTION: Use only specified brake fluid. Do not 1. For 4–Wheel Antilock Brake System (ABS) equipped
use any fluid which contains a petroleum base. Do vehicle, be sure to remove the ABS main fuse 40A
not use a container which has been used for located at the relay and fuse box before bleeding air. If
petroleum based fluids or a container which is wet you attempt to bleed air without removing the main
with water. Petroleum based fluid will cause swelling fuse, air cannot be let out thoroughly, and this may
and distortion of rubber parts in the hydraulic brake cause damage to the hydraulic unit. After bleeding air,
system. Water mixed with brake fluid lowers the fluid be sure to replace the ABS main fuse back to its
boiling point. Keep all fluid containers capped to original position.
prevent contamination.
2. Set the parking brake completely, then start the
Always fill the master cylinder reservoir when the en- engine.
gine is cold.
Never allow the brake fluid to come in contact with NOTE: The vacuum booster will be damaged if the
the painted surfaces. bleeding operation is performed with the engine off.
The master cylinder reservoir must be kept properly 3. Remove the master cylinder reservoir cap.
filled to ensure adequate reserve and to prevent air 4. Fill the master cylinder reservoir with brake fluid.
and moisture from entering the hydraulic system. Keep the reservoir at least half full during the air
However, because of expansion due to heat ab- bleeding operation
sorbed from the brakes and the engine, the reservoir
must not be overfilled. The brake fluid reservoir is on 5. Always use new brake fluid for replenishment.
the master cylinder, which is located under the hood 6. In replenishing brake fluid, take care that air bubbles
on the left side of the cowl. Thoroughly clean reser- do not enter the brake fluid.
voir cap before removal to avoid getting dirt into res- When the master cylinder is replaced or overhauled,
ervoir. Remove cup and diaphragm. Add fluid as re- first bleed the air from the master cylinder, then from
quired to bring level to the “MAX” mark on the each wheel cylinder and caliper following the
reservoir tank. Use “DOT 3” Hydraulic Brake Fluid. If procedures described below.
the fluid cap diaphragm is stretched, return it to the Bleeding the Master Cylinder
original position before installing. 7. Disconnect the rear wheel brake pipe (1) from the
master cylinder.
Deterioration of Brake Fluid Check the fluid level and replenish as necessary. If
replenished, leave the system for at least one minute.
Using any other brake fluid than specified or brake fluid
with mineral oil or water mixed in will drop the boiling point 8. Depress the brake pedal slowly once and hold it
of brake fluid. It may, in turn, result in vapor lock or depressed.
deteriorated rubber parts of the hydraulic system. Be sure 9. Completely seal the delivery port of the master
to change the brake fluid at specified intervals. cylinder with your finger, where the pipe was
If the rubber parts are deteriorated, remove all the system disconnected then release the brake pedal slowly.
parts and clean them with alcohol. Prior to reassembly, 10. Release your finger from the delivery port when the
dry the cleaned parts with air to remove the alcohol. brake pedal returns completely.
Replace all the hoses and rubber parts of the system.
11. Repeat steps 7 through 9 until the brake fluid comes
out of the delivery port during step 7.
Leakage of Brake Fluid NOTE: Do not allow the fluid level in the reservoir to go
With engine idling, set shift lever in the neutral position below the half–way mark.
and continue to depress brake pedal at a constant pedal
application force. 12. Reconnect the brake pipe (1) to the master cylinder
Should the pedal stroke become deeper gradually, a and tighten the pipe.
leakage from the hydraulic pressure system is possible. 13. Depress the brake pedal slowly once and hold it
Make sure by visual check that there is no leak. depressed.
14. Loosen the rear wheel brake pipe (1) at the master
cylinder.
Bleeding Brake Hydraulic System
15. Retighten the brake pipe, then release the brake
A bleeding operation is necessary to remove air from the pedal slowly.
hydraulic brake system whenever air is introduced into
the hydraulic system. It may be necessary to bleed the
hydraulic system at all four brakes if air has been
introduced through a low fluid level or by disconnecting
brake pipes at the master cylinder. If a brake pipe is
disconnected at one wheel, only that wheel
cylinder/caliper needs to be bled. If the pipes are
disconnected at any fitting located between the master
16. Repeat steps 13 through 15 until no air comes out of 27. Depress the brake pedal to check if you feel
the port when the brake pipe is loosened “sponginess” after the air has been removed from all
wheel cylinders and calipers.
NOTE: Be very careful not to allow the brake fluid to come
in contact with painted surfaces. If the pedal feels “spongy”, the entire bleeding
procedure must be repeated.
28. After the bleeding operation is completed on the each
individual wheel, check the level of the brake fluid in
the reservoir and replenish up to the “MAX” level as
necessary.
29. Attach the reservoir cap.
If the diaphragm inside the cap is deformed, reform
it and install.
30. Stop the engine.
Flushing Brake Hydraulic System

It is recommended that the entire hydraulic system be
thoroughly flushed with clean brake fluid whenever new
parts are installed in the hydraulic system. Approximately
one quart of fluid is required to flush the hydraulic system.
The system must be flushed if there is any doubt as to the
grade of fluid in the system or if fluid has been used when
it contains the slightest trace of mineral oil. All rubber
330RS023
parts that have been subjected to a contaminated fluid
17. Bleed the air from the front wheel brake pipe must be replaced.
connection (2) by repeating steps 7 through 16.
Bleeding the Caliper Brake Pipes and Hoses
18. Bleed the air from each wheel in the order listed The hydraulic brake system components are
below: interconnected by special steel piping and flexible hoses.
D Right rear caliper Flexible hoses are used between the frame and the front
D Left rear caliper calipers, the frame and rear axle case and the rear axle
and the rear calipers.
D Right front caliper When the hydraulic pipes have been disconnected for
D Left front caliper any reason, the brake system must be bled after
reconnecting the pipe. Refer to “Bleeding the Brake
Conduct air bleeding from the wheels in the above Hydraulic System” in this section.
order. If no brake fluid comes out, it suggests that air
is mixed in the master cylinder. In this case, bleed air
from the master cylinder in accordance with steps 7 Brake Hose Inspection
through 17, and then bleed air from the caliper. The brake hose should be inspected at least twice a year.
19. Place the proper size box end wrench over the The brake hose assembly should be checked for road
bleeder screw. hazard, cracks and chafing of the outer cover, and for
20. Cover the bleeder screw with a transparent tube, and leaks and blisters. Inspect for proper routing and
submerge the free end of the transparent tube in a mounting of the hose. A brake hose that rubs on
transparent container containing brake fluid. suspension components will wear and eventually fail. A
light and mirror may be needed for an adequate
21. Pump the brake pedal slowly three (3) times inspection. If any of the above conditions are observed on
(once/sec), then hold it depressed. the brake hose, adjust or replace the hose as necessary.
22. Loosen the bleeder screw until fluid flows through the
tube. CAUTION: Never allow brake components such as
calipers to hang from the brake hoses, as damage to
23. Retighten the bleeder screw. the hoses may occur.
24. Release the brake pedal slowly.
25. Repeat steps 21 through 24 until the air is completely
removed.
It may be necessary to repeat the bleeding procedure
10 or more times for front wheels and 15 or more
times for rear wheels.
26. Go to the next wheel in the sequence after each wheel
is bled.
Be sure to monitor reservoir fluid level.
Front / Rear Caliper Brake Hose

Front / Rear Caliper Brake Hose and Installation
Associated Parts To install, follow the removal steps in the reverse order,
1. Tighten the brake pipes to the specified torque
NOTE: Always use new gaskets and be sure to put the
hooked edge of the flexible hose end into the anti–rotation
cavity.
After installing the brake hoses, bleed the brakes as
described in this section.
352RW001
Legend
(1) Bolt and Gasket
(2) Clip
(3) Hose
(4) Brake Pipe
Removal
1. Raise the vehicle and support it with suitable safety
stands.
2. Remove the wheel and tire assembly.
3. Clean dirt, grease, and other foreign material off the
hose fittings at both ends.
4. Disconnect brake pipe.
5. Remove clip.
6. Remove bolt and gasket.
7. Remove hose.
Rear Axle Brake Hose

Rear Axle Brake Hose and Associated Installation
Parts To install, follow the removal steps in the reverse order,
1. Tighten the brake pipes to the specified torque
Sems bolts
Flange bolts
After installing the brake hoses, bleed the brakes as
352RW002
Legend
(1) Brake Pipe
(2) Clip
(3) Bolt
(4) Brake Pipe
(5) Hose
Removal
1. Raise the vehicle and support it with suitable safety
stands.
2. Remove wheel and tire assembly.
3. Clean dirt, grease, and other foreign material off the
hose fittings at both ends.
4. Disconnect brake pipe.
5. Remove clip.
6. Remove brake pipe.
7. Remove bolt.
8. Remove hose.
Brake Pipe
1. Raise the vehicle and support it with suitable safety To install, follow the removal steps in the reverse order,
stands. noting the following points:
2. Remove wheel and tire assembly as necessary. 1. Tighten the brake pipes to the specified torque.
3. Clean dirt, grease, and other foreign material off the Master cylinder side
pipe fittings at both ends. Torque: 12 N·m (104 lb in)
4. Remove brake pipe (1).
Other
After installing the brake pipes, bleed the brakes as
330RW001
5. Remove plastic clip (2).
330RW002
P & B (Proportioning and Bypass) Valve

P & B (Proportioning and Bypass) Removal
Valve Sectional View 1. The P&B valve is not repairable and must be replaced
as a complete assembly. Care must be taken to
prevent brake fluid from contacting any painted
surface.
2. Remove hydraulic pipes (1) and plug (1) the pipes to
prevent the loss of fluid or the entrance of dirt.
3. Remove bolt (3).
4. Remove P&B valve (2).
350RW001
Legend
(1) Master Cylinder (Secondary)
(2) Master Cylinder (Primary)
(3) Rear Brake
(4) Front Brake
The P&B valve contains two sections, each serving a

different function.
The proportioning section of the P&B valve proportions
outlet pressure to the rear brakes after a predetermined
rear input pressure has been reached. This is done to
prevent rear wheel lock up on the vehicles with light rear
wheel loads. The valve has a pass feature which assures
full system pressure to the rear brakes in the event of front
brake system malfunction. Also full front pressure is
retained in the event of rear brake malfunction.
The combination valve has a pressure differential
warning switch which is designed to constantly compare 350RW015
front and rear brake pressure from the master cylinder

and turn on the brake system warning light on the
instrument panel in the event of a front or rear system
Installation
malfunction. The valve and switch are so designed that 1. Install P&B valve (2).
the switch will latch in the warning position once a 2. Install bolt (3) and tighten the bolt to the specified
malfunction has occured. The only way the light can be torque.
turned off is to repair the malfunction and apply a pedal
forced required to developed line pressure. The P&B Torque: 13 N·m (113 lb in)
valve is not repairable and must be replaced as a 3. Install hydraulic pipes (1) and tighten the bolt to the
complete assembly. specified torque.
4. After installing the brake pipes, bleed the brakes
refering to “Bleeding Brake Hydraulic System” in this
section.

E05RW001
Brake Pedal
Checking Pedal Height
The push rod serves as the brake pedal stopper when the
pedal is fully released. Brake pedal height adjustment
should be performed as follows:
Adjust Brake Pedal
310RY00001
NOTE: While adjusting the stoplight switch, make sure

that the threaded part of the stoplight switch does not
push the brake pedal.
h. Tighten the stoplight switch lock nut.
i. Connect the stoplight switch connector.
310RW001
1. Measure the brake pedal height after making sure the

pedal is fully returned by the pedal return spring. Checking Pedal Travel
Pedal height must be measured after starting the
engine and receiving it several times.
Pedal Free Play : 6-10 mm (0.23-0.39 in)
Pedal Free Play : 208-218 mm (8.19-8.58 in)
NOTE: Pedal free play must be measured after turning
off the engine and stepping on the brake pedal firmly five
times or more.
2. If the measured value is not within the above range,
adjust the brake pedal as follows:
a. Disconnect the stoplight switch connector.
b. Loosen the stoplight switch lock nut (1).
c. Rotate the stoplight switch so that is moves away
from the brake pedal.
d. Loosen the lock nut on the push rod.
e. Adjust the brake pedal to the specified height by
rotating the push rod in the appropriate direction.
f. Tighten the lock nut to the specified torque. 310RW001
Torque: 20 N·m (15 lb ft) 1. Pedal height (3) must be measured after starting the
g. Adjust the stoplight switch to the specified engine and revving it several times to apply vacuum
clearance (between the switch housing and the to the vacuum booster fully.
brake pedal) by rotating the switch housing. NOTE: Pedal height (3) must be 100 mm (3.9 in) or more
Clearance : 0–0.2 mm (0–0.008 in) when about 50 kg (110.25 lb) of stepping force is applied.
2. If the measured value is lower than the above range,
air existing in the hydraulic system is suspected.
Perform the bleeding procedure.
Brake Pedal and Associated Parts
310RY00002
Legend (7) Front Console Assembly

(1) Nut (8) Instrument Panel Driver Lower Cover
(2) Stoplight Switch Connector (9) Return Spring
(3) Fulcrum Pin (10) Brake Pedal
(4) Driver Knee Bolster Assembly (11) Snap Pin
(5) Lower Cluster Assembly (12) Pin
(6) Shift Knob (13) Anti–theft Controller
1. Remove shift knob. 1. Install brake pedal.
2. Remove front console assembly. 2. Install fulcrum pin and apply grease to the entire
3. Remove lower cluster assembly. circumference of the fulcrum pin.
4. Remove instrument panel driver lower cover. Torque: 33 N·m (24 lb ft)
5. Remove driver knee bolster assembly. 3. Install nut and tighten the nut to the specified torque.
6. Remove anti–theft controller. Torque: 33 N·m (24 lb ft)
7. Remove stoplight switch connector. 4. Install pin and apply grease to the entire
8. Remove return spring. circumference of the push rod pin.
9. Remove snap pin. 5. Install snap pin and adjust the pedal free travel
10. Remove pin. Refer to “Brake Pedal Adjustment” previously in this
11. Remove nut. section.
12. Remove fulcrum pin. 6. Install return spring.
13. Remove brake pedal. 7. Connect stoplight switch connector.
8. Connect anti–theft connector.
9. Install driver knee bolster assembly.
10. Install instrument panel driver lower cover.
11. Install lower cluster assembly. 13. Install shift knob.
12. Install front console assembly.
Stoplight Switch
Removal
1. Remove shift knob.
4. Remove instrument panel driver lower cover.
5. Remove driver knee bolster assembly.
6. Remove stoplight switch connector (3).
7. Remove lock nut (1).
8. Remove switch (2).
310RY00001
2. Install lock nut.

3. Connect stoplight switch connector.
4. Install driver knee bolster assembly.
5. Install instrument panel driver lower cover.
6. Install lower cluster assembly.
8. Install shift knob.
310RW004
Installation
1. Install switch and adjust the stoplight switch to the
specified clearance (between the switch housing and
the brake pedal) by rotating the switch housing.
Clearance (1): 0-0.2 mm (0-0.009 in)
NOTE: While adjusting the installation of the stoplight
switch, make sure that the threaded part of the stoplight
switch does not push the brake pedal.

Pedal free play 6–10 mm (0.23 –0.39 in)
Pedal Height 208–218 mm (819–8.58 in)
E05RW002
Fluid Reservoir Tank

Fluid Reservoir Tank and Associated Parts
330RW003
Legend (3) O–ring

(1) Fluid Reservoir (4) Retainer
(2) Electrical Connector
NOTE: Before removing the fluid reservoir, remove the To install, follow the removal steps in the reverse order,
brake fluid from the fluid reservoir. noting the following points:
1. O–ring (1) must be set onto the fluid reservoir (2),
1. Disconnect electrical connector. before installing fluid reservoir.
2. Remove retainer (1).
330RW005
330RW004
3. Remove fluid reservoir and the fluid lever sensor built

into the fluid reservoir . The fluid level sensor cannot
be removed for servicing.
4. Remove O–ring.
Master Cylinder Assembly

Master Cylinder Assembly and Associated Parts
330RW006
Legend (4) P&B Valve and Bracket

(1) Electrical Connector (5) Brake Pipes
(2) Master Cylinder (6) Spacer and 2 gaskets
(3) 2 attaching Nuts
Removal 4. Remove P&B valve and bracket.

5. Remove master cylinder.
CAUTION: When removing the master cylinder from
6. Remove spacer and the 2 gaskets.
the vacuum booster, be sure to get rid of the internal
negative pressure of the vacuum booster (by, for
instance, disconnecting the vacuum hose) in Inspection and Repair
advance.
If any negative pressure remains in the vacuum Master Cylinder
booster, the piston may possibly come out when the The master cylinder is not repairable and must be
master cylinder is being removed, letting the brake replaced as a complete assembly if found defective.
fluid run out.
While removing the master cylinder, further, do not Inspection
hold the piston as it can be easily pulled out. Excessive brake pedal travel, malfunction or dragging
Outside surface of the piston is the surface on which brake suggests that the master cylinder is defective. In
seals are to slide. Care should be taken to keep the such cases perform the following visual check.
surface free of cuts and dents.
Visual Check
1. Disconnect electrical connector. Make parts replacement as required if wear, distortion,
2. Remove brake pipes after disconnecting the brake nicks, cuts, corrosion, or other abnormal conditions are
pipe, cap or tape the openings of the brake pipe to found through the following parts inspection:
prevent the entry of foreign matter. D Master cylinder body
3. Remove 2 attaching nuts. D Fluid reservoir
D O–ring There should be a pressure increase of 0.5 kg/cm@ or
more.
Functional Inspection of Master Cylinder
Piston
Push the primary piston (1) with your fingers to check that
it travels smoothly. If the motion is questionable, replace
the master cylinder as a complete assembly.
330RW009
NOTE: When checking the front (or primary) side, be

sure to mount the master cylinder plug in the rear (or
secondary) port.
330RW007
“0” Line “5” Line
Apply air pres- No pressure Pressure in-
Functional Inspection of Master Cylinder sure to the front rise. crease of 0.5
Inspect the master cylinder for function as follows. If any and rear ports kg/cm@ or more
abnormal function is found, replace with a new one.
Remarks Checks port Checks air
(including the master cylinder attachment and master into the tightness of the
cylinder plug (7)) atmospheric pressure
Install the primary piston holder (3) J–39242 onto the pressure chamber
master cylinder (4). Make sure the spacer (2) (2 bolts) chamber
with its adjusting bolt is screwed in up to the “0” line
NOTE:
1. Do not use an air compressor, as the air from the
compressor is mixed with compressor oil.
2. When installing the master cylinder onto the vacuum
booster, always adjust the vacuum booster push rod.
(Refer to “Vacuum Booster” in this section).
3. After the master cylinder is installed onto the vehicle,
check for leakage, pedal travel and pedal free play.
Installation
1. Install spacer and the 2 gaskets.
2. Install master cylinder, when replacing the master
cylinder or vacuum booster or both, always measure
the vacuum booster push rod protrusion and adjust it
as necessary (Refer to “Vacuum Booster” in section).
3. Install P&B valve and bracket.
330RW008 4. Install 2 attaching nuts and tighten the attaching nuts
Connect the master cylinder attachment (5) J–39242 with to the specified torque.
the end of the radiator cap tester (6) J–24460–01, and
apply air pressure with the cap tester. Make sure there is
no rise in pressure and that with the adjusting bolt further
screwed in 5 mm (align the adjusting bolt to the “5” line).
5. Install brake pipes and tighten the brake pipe to the
specified torque.
Master cylinder side
Others
6. Connect electrical connector.

Type Dual–circuit
Piston bore 25.4 mm (1.000 in)
diameter
E05RW003
Special Tools
TOOL NO.
ILLUSTRATION
TOOL NAME
J-39242
Primary Piston Holder
(including master
cylinder attachment and
master cylinder plug
J-24460-01
Radiator Cap Tester
Vacuum Booster Assembly

Vacuum Booster Assembly and Associated Parts
331RW001
Legend (4) Master Cylinder

(1) Pin (5) Vacuum Booster
(2) Vacuum Booster Fixing Nut (6) Snap Pin
(3) Vacuum Hose
Removal Outside surface of the piston is the surface on which

seals are to slide. Care should be taken to keep the
1. Before removing the vacuum booster assembly, surface free of cuts and dents.
disconnect and remove the brake pipes. 3. Remove vacuum hose.
2. Remove master cylinder, refer to “Master Cylinder 4. Disconnect the yoke clevis from the brake pedal.
Removal” in this section.
5. Remove vacuum booster fixing nut.
CAUTION: When removing the master cylinder from 6. Remove vacuum booster.
the vacuum booster, be sure to get rid of the internal
negative pressure of the vacuum booster (by, for
instance, disconnecting the vacuum hose) in Inspection and Repair
advance.
If any negative pressure remains in the vacuum Vacuum Hose
booster, the piston may possibly come out when the 1. Inspect the check valve (2), which is installed inside
master cylinder is being removed, letting the brake the vacuum hose.
fluid run out.
2. Air should pass freely from the vacuum booster (3) to
While removing the master cylinder, further, do not the engine (1).
hold the piston as it can be easily pulled out.
3. Air should not pass from the engine (1) to the vacuum 3. Set push rod gauge J–39216 on vacuum booster, and
booster (3). If it does, the check valve is inoperative apply negative pressure by means of vacuum pump
and the vacuum hose built check valve must be J–23738–A so that the pressure in the vacuum
replaced. booster becomes 500 mm Hg.
NOTE: Be sure to apply NEGATIVE pressure after
installing a push rod gauge on the vacuum booster.
360RY00002
Installation 331RS004
1. Install vacuum booster and vacuum booster push rod 4. Measure dimension (4).
adjustment. Dimension (4) (Standard): –0.1–0.1 mm
(–0.0039–0.0039 in)
NOTE: When replacing either the master cylinder or
vacuum booster, be sure to measure push rod, and adjust
if required.
2. Remove retainer from vacuum booster front shell
using a small screwdriver. Then gently draw plate and
seal assembly out of the shell inside.
331RW002
331RS003
5. If dimension (4) is out of the standard range, adjust
push rod using the Push Rod Support J–39241.
331RW003
6. Mount plate and seal assembly in vacuum booster

front shell. Then install the retainer.
7. Install vacuum booster fixing nut and tighten the
specified torque.
8. Install yoke clevis.
9. Connect vacuum hose and make sure that the arrow
on the hose points in the direction of the engine.
10. Install master cylinder, refer to “Master Cylinder
Installation” in this section.
Exterior Components
Exterior Components and Associated Parts
331RW004
Legend (6) Filter

(1) Yoke Clevis (7) 2 Gaskets and Spacer
(2) Lock Nut (8) Vacuum Booster
(3) Retaining Clip (9) Retainer
(4) Valve Body Guard (10) Plate and Seal Assembly
(5) Silencer (11) Master Cylinder
Removal
1. Remove master cylinder, refer to “Master Cylinder” in
this section.
2. Remove vacuum booster, refer to “Vacuum Booster”
in this section.
3. Remove yoke clevis.
4. Remove lock nut.
5. Remove retaining clip.
6. Remove valve body guard.
7. Remove silencer.
8. Remove filter.
9. Remove 2 gaskets and spacer.
10. Remove retainer, use a small screwdriver to pry out
the retainer. Gently pull out the plate and seal
assembly from the shell.
331RS003
11. Remove plate and seal assembly. 2. Install retainer.
3. Install 2 gaskets and spacer.
Inspection and Repair 4. Install filter.
5. Install silencer.
Visual Check
6. Install valve body guard.
Make necessary parts replacement if cuts, nicks,
7. Install retainer.
excessive wear, or other abnormal conditions are found
through inspection. Check the following parts: 8. Install lock nut and tighten to the specified torque.
D Yoke clevis Torque: 20 N·m (15 lb ft)
D Valve body guard 9. Install yoke clevis.
D Silencer 10. Install vacuum booster, refer to “Vacuum Booster” in
D Filter plate and seal assembly this section.
11. Install master cylinder, refer to “Master Cylinder” in
this section and after installation, perform brake pedal
Installation check and adjustment. Refer to “Brake Pedal” in this
1. Install plate and seal assembly. section.
Vacuum Booster Overhaul

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

Vacuum booster diaphragm diameter (Front) 205 mm (8.07 in)
Vacuum booster diaphragm diameter (Rear) 230 mm (9.06 in)
Push rod stroke More than 32.0 mm (1.26 in)
Plunger diameter 10.25 mm (0.40 in)
Push rod diameter 27.4 mm (1.08 in)
C05RT003
Special Tools
TOOL NO.
ILLUSTRATION
TOOL NAME
J-39216
Push Rod Gauge
J-23738-A
Vacuum Pump
J-39241
Push Rod Support
Front Disc Brake Pads

Front Disc Brake Pads Inspection
Check the outer pad by looking at each caliper from
above. Check the thickness on the inner pad by looking
down through the inspection hole in the top of the caliper.
Whenever the pad is worn to about the thickness of the
pad base, the pad should be removed for further
measurements. The pad should be replaced anytime the
pad thickness (1) is worn to within 1.00 mm (0.039 in) of
the pad itself.
The disc pads have a wear indicator that makes a noise
when the pad wears to where replacement is required.
Minimum limit (1): 1.0 mm (0.039 in)
302RS002
Front Disc Brake Pads and Associated Parts
302RW003
Legend (3) Pad Assembly

(1) Lock Bolt (4) Clip
(2) Caliper Assembly (5) Outer Side
Removal
NOTE: If a squealing noise occurs from the front brake
while driving, check the pad wear indicator plate. If the
indicator plate contacts the rotor, the disc pad assembly
should be replaced.
D Draw out two–thirds of the brake fluid from the
reservoir.
D Raise the vehicle and support it with suitable safety
stands.
1. Remove wheel and tire assembly, refer to “Wheels
and Tires System” in Section 3E.
2. Remove lock bolt (1).
302RS005
2. Install pad assembly with shim and apply special

grease (approximately 0.2 g) to both contacting
surfaces of the inner shims (2). Wipe off extruded
grease after installing.
302RW004
3. Remove caliper assembly and support the caliper

assembly so that the brake hose is not stretched or
damaged.
4. Remove pad assembly with shim.
5. Remove Clip.
Installation
1. Install clip.
302RW005
Legend
(2) Inner Shim
(3) Wear Indicator
(4) Inner Side
302RW006 302RW007
3. Install caliper assembly, use adjustable pliers to 5. Install wheel and tire assembly, refer to “Wheels and
bottom the piston into the caliper bore. Tires System” in Section 3E.
Be careful do not damage the piston boot and do not 6. Pump the brake pedal several times to make sure that
damage the flexible hose by twisting or pulling it. the pedal is firm. Check the brake fluid level in the
reservoir after pumping the brakes.
302RS008
4. Install lock bolt (5) and tighten the bolt to the specified
torque.
Front Disc Brake Rotor

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

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

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

Accurate control of the rotor tolerances is necessary for
proper performance of the disc brakes. Machining of the
rotor should be done only with precision equipment. All
brake rotors have a minimum thickness dimension cast
into them. This dimension is the minimum wear
dimension and not a refinish dimension. The minimum
wear dimension is 24.60 mm (0.969 in). The minimum
refinish dimension is 24.97 mm (0.983 in).
When refinishing rotors, always use sharp cutting tools or
bits. Dull or worn tools leave a poor surface finish which
will affect initial braking performance. Vibration
dampening attachments should always be used when
411RS019 refinishing braking surfaces. These attachments
eliminate tool chatter and will result in better surface
Parallelism finish.
Parallelism is the measurement of thickness of the rotor
at four or more points around the circumference of the
rotor. All measurements must be made 29 mm (1.14 in)
from the edge of the rotor.
After refinishing, replace any rotor that does not meet the
minimum thickness of 24.97 mm (0.983 in). Do not use a
brake rotor that will not meet the specification.
Minimum wear dimension: 24.60 mm (0.969 in)
Refinish dimension: 24.97 mm (0.983 in)
411RW003
Front Disc Brake Caliper Assembly

Front Disc Brake Caliper Assembly and Associated Parts
302RW008
Legend (4) Caliper Assembly

(1) Guide Bolt (5) Clip
(2) Brake Flexible Hose (6) Support Bracket with Pad Assembly
(3) Lock Bolt (7) Pad Assembly
Removal
1. Raise the vehicle and support with suitable safety
stands.
2. Wheel and tire assembly, refer to “Wheels and Tires
System” in Section 3E.
3. Remove the bolt and gaskets, then disconnect the
flexible hose from the caliper and after disconnecting
the flexible hose (1), cap or tape the openings to
prevent entry of foreign material.
302RW009
4. Since the brake fluid flows out from the connecting 2. Install pad assembly with shim and apply special
coupler, place a drain pan under the vehicle. grease (approximately 0.2 g) to both contacting
5. Remove guide bolt (2). surfaces of the inner shims (6). Wipe off extruded
6. Remove lock bolt (3).
302RW011
302RW010
7. Remove caliper assembly. Legend

8. Remove support bracket with pad assembly and take (4) Inner Shim
care not to damage the flexible brake hose when (5) Wear Indicator
removing the support bracket. (6) Inner Side
9. Remove pad assembly with shim and mark the lining
locations if they are to be reinstalled. 3. Install support bracket and tighten the bolt (7) to the
10. Remove clip. specified torque.
Installation
1. Install clip.
302RW012
4. Install caliper assembly.
302RS005
5. Install lock bolt (9) and guide bolt (8) and tighten the
302RW013
6. Install brake flexible hose, always use new gaskets

and be sure to put the hooked edge of the flexible
hose end into the anti–rotation cavity then tighten the
I–bolt (10) to the specified torque.
302RW014
7. Install wheel and tire assembly, refer to “Wheels and

Tires System” in Section 3E.
8. Bleed brakes. Refer to “Hydraulic Brakes” in this
section.
Front Disc Brake Caliper

Front Disc Brake Caliper Disassembled View
302RW015
Legend (5) Dust Boot: Guide Bolt and Lock Bolt

(1) Guide Bolt (6) Piston Seal
(2) Lock Bolt (7) Piston
(3) Bleeder with Cap (8) Dust Boot: Piston
(4) Caliper Body (9) Dust Boot Ring
Disassembly
1. Remove guide bolt.
2. Remove lock bolt.
3. Remove dust boot: guide bolt and lock bolt.
4. Remove dust boot ring, using a small screwdriver,
remove the dust boot ring.
302RS016
5. Insert a block of wood into the caliper and force out Reassembly
the piston by blowing compressed air into the caliper
at the flexible hose attachment. This procedure must 1. Install caliper body.
be done prior to removal of the dust boot. 2. Install bleeder with cap and tighten the cap to the
WARNING: DO NOT PLACE YOUR FINGERS IN specified torque.
FRONT OF THE PISTON IN AN ATTEMPT TO CATCH Torque: 8 N·m (69 lb in)
OR PROTECT IT WHEN APPLYING COMPRESSED 3. Install piston seal and apply special rubber grease to
AIR. THIS COULD RESULT IN PERSONAL INJURY. the piston seal and cylinder wall, then insert the piston
CAUTION: Use just enough air to ease the piston seal into the cylinder. The special rubber grease is
out of the bore. If the piston is blown out, it may be included in the repair kit.
damaged.
302RS018
302RS017
4. Install piston.
6. Remove dust boot: piston. 5. Install piston dust boot; when inserting the piston into
7. Remove piston seal. the cylinder, use finger pressure only and do not use a
mallet or other impact tool, since damage to the
8. Remove bleeder with cap. cylinder wall or piston seal can result.
9. Remove caliper body.

Make necessary parts replacement, if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
D Rotor
D Cylinder body
D Cylinder bore
D Piston
D Guide bolt, lock bolt
D Support bracket
NOTE: The piston seal, boot ring and dust boot are to be
replaced each time the caliper is overhauled. Discard
these used rubber parts and replace them with new ones.
302RS019
6. Install dust boot ring and apply special grease
(approximately 1 g) to the piston and attach the dust
boot to the piston and caliper. Insert the dust boot ring
into the dust boot.
302RS020
7. Install guide bolt and lock bolt dust boot.

8. Install lock bolt and guide bolt and tighten the bolt to
9. Install the dust boot on the support bracket after
applying special grease (approximately 1 g) onto the
dust boot inner surface. Apply special grease onto the
lock bolt and guide bolt setting hole of the support
bracket.
302RS021

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

Brake Pads Inspection
Check the outer pads by looking at each caliper from
above. Check the thickness on the inner pad by looking
down through the inspection hole in the top of the caliper.
Whenever the pad is worn to about the thickness of the
pad base, the pad should be removed for further
measurements. The pad should be replaced anytime the
pad thickness (1) is worn to within 1.0 mm (0.039 in) of the
pad itself.
The disc pads have a wear indicator that makes a noise
when the pad wears to where replacement is required.
Minimum limit (1): 1.0 mm (0.039 in)
302RW016
Brake Pads and Associated Parts
306RW001
Legend (3) Lock Bolt

(1) Caliper Assembly (4) Pad Assembly
(2) Clip
Removal
NOTE: If a squealing noise occurs from the rear brake
while driving, check the pad wear indicator plate. If the
indicator plate contacts the rotor, the disc pad assembly
should be replaced.
D Draw out two–thirds of the brake fluid from the
reservoir.
D Raise the vehicle and support it with suitable safety
stands.
2. Remove lock bolt (1)
306RW003
2. Install pad assembly with shim and apply special

surfaces of the inner shims. Wipe off extruded grease
after installing.
306RW002
3. Remove caliper assembly and support the caliper

assembly so that the brake hose is not stretched or
damaged.
4. Remove pad assembly with shim.
5. Remove clip.
Installation
1. Install clip (2).
306RW004
Legend
(3) Inner Shim
(4) Wear Indicator
306RW005 306RW006
3. Install caliper assembly, use adjustable pliers to

bottom the piston into the caliper bore. Be careful not
to damage the piston dust boot and do not damage
the flexible hose by twisting or pulling it.
302RS008
4. Install lock bolt (5) and tighten the bolt to the specified
torque.
5. Install wheel and tire assembly, refer to “Wheels and
Tires System” in Section 3E.
6. Pump the brake pedal several times to make sure that
the pedal is firm. Check the brake fluid level in the
reservoir after pumping the brakes.
Rear Disc Brake Rotor

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

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

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

Accurate control of the rotor tolerances is necessary for
proper performance of the disc brakes. Machining of the
rotor should be done only with precision equipment. All
brake rotors have a minimum thickness dimension cast
into them. This dimension is the minimum wear
dimension and not a refinish dimension. The minimum
wear dimension is 16.6 mm (0.654 in). The minimum
refinish dimension is 16.97 mm (0.668 in).
When refinishing rotors, always use sharp cutting tools or
bits. Dull or worn tools leave a poor surface finish which
will affect initial braking performance. Vibration
dampening attachments should always be used when
refinishing braking surfaces. These attachments
411RS019 eliminate tool chatter and will result in better surface
finish.
Parallelism
Parallelism is the measurement of thickness of the rotor
at four or more points around the circumference of the
rotor. All measurements must be made 22 mm (0.87 in)
from the edge of the rotor.
After refinishing, replace any rotor that does not meet the
minimum thickness of 16.97 mm (0.668 in). Do not use a
brake rotor that will not meet the specification.
Minimum wear dimension: 16.6 mm (0.654 in)
Refinish dimension: 16.97 mm (0.668 in)
420RW002
Rear Drum (In Disc) Inside Diameter

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

Rear Disc Brake Caliper Assembly and Associated Parts
306RW007
Legend (4) Support Bracket

(1) Brake Flexible Hose (5) Guide Bolt
(2) Clip (6) Pad Assembly with Shim
(3) Lock Bolt (7) Caliper Assembly
Removal 4. Since the brake fluid flows out from the connecting
coupler, place a drain pan under the vehicle.
1. Raise the vehicle and support with suitable safety 5. Remove lock bolt (2).
stands.
6. Remove guide bolt (3).
3. Remove the bolt and gaskets, then disconnect the
flexible hose from the caliper and after disconnecting
the flexible hose (1), cap or tape the openings to
prevent entry of foreign material.
306RW009
7. Remove caliper assembly.

8. Remove support bracket with pad assembly and take
care not to damage the flexible brake hose when
removing the support bracket.
306RW008
9. Remove pad assembly (with shim) and mark the
lining locations if they are to be reinstalled.
10. Remove clip. 3. Install support bracket and tighten the bolt (7) to the
specified torque.
Installation Torque: 103 N·m (76 lb ft)
1. Install clip (4).
306RW012
4. Install caliper assembly.

306RW010
5. Install lock bolt and guide bolt (8) and tighten the bolt
2. Install pad assembly (with shim) and apply special
surfaces of the inner shims (5). Wipe off extruded Torque: 44 N·m (32 lb ft)
306RW013
306RW011
Legend
(5) Inner Shim
(6) Wear indicator
6. Install brake flexible hose, always use new gaskets
and be sure to put the hooked edge of the flexible
hose end into the anti–rotation cavity then tighten the
I–bolt (9) to the specified torque.
302RW017
7. Install the wheel and tire assembly, refer to “Wheels

8. Bleed brakes. Refer to “Hydraulic Brakes” in this
section.
Rear Disc Brake Caliper

Rear Disc Brake Caliper Disassembled View
306RW014
Legend (5) Piston Seal

(1) Guide Bolt (6) Piston
(2) Lock Bolt (7) Dust Boot: Piston
(3) Bleeder with Cap (8) Dust Boot Ring
(4) Caliper Body (9) Dust Boot: Guide Bolt and Lock Bolt
Disassembly
1. Remove guide bolt.
2. Remove lock bolt.
3. Remove dust boot; guide bolt and lock bolt.
4. Remove the dust boot ring using a small screwdriver.
302RS016
5. Insert a block of wood into the caliper and force out Reassembly
the piston by blowing compressed air into the caliper
at the flexible hose attachment. This procedure must 1. Install caliper body.
be done prior to removal of the dust boot. 2. Install bleeder with cap and tighten the cap to the
WARNING: DO NOT PLACE YOUR FINGERS IN specified torque.
FRONT OF THE PISTON IN AN ATTEMPT TO CATCH Torque: 8 N·m (69 lb ft)
OR PROTECT IT WHEN APPLYING COMPRESSED 3. Install piston seal and apply special rubber grease to
AIR. THIS COULD RESULT IN PERSONAL INJURY. the piston seal and cylinder wall, then insert the piston
CAUTION: Use just enough air to ease the piston seal into the cylinder. The special rubber grease is
out of the bore. If the piston is blown out, it may be included in the repair kit.
damaged.
302RS018
302RS017
4. Install piston.
6. Remove dust boot: piston. 5. Install piston dust boot; when inserting the piston into
7. Remove piston seal. the cylinder, use finger pressure only and do not use a
mallet or other impact tool, since damage to the
8. Remove bleeder with cap. cylinder wall or piston seal can result.
9. Remove caliper body.

Make necessary parts replacement, if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
D Rotor
D Cylinder body
D Cylinder bore
D Piston
D Guide bolt, lock bolt
D Support bracket
NOTE: The piston dust seal and dust boot are to be
replaced each time the caliper is overhauled. Discard
these used rubber parts and replace with new ones.
302RS019
6. Install dust boot ring and apply special grease
(approximately 1g) to the piston and attach the dust
boot to the piston and caliper. Insert the dust boot ring
into the dust boot.
302RS020
7. Install guide bolt and lock bolt dust boot.

8. Install lock bolt and guide bolt and tighten the bolt to
9. Install the dust boot on the support bracket after
applying special grease (Approx. 1g) onto the dust
boot inner surface. Also apply special grease onto the
lock bolt and guide bolt setting hole of the support
bracket.
302RS021

Type Floating, pin slide
Pad dimension 33 cm@ (5.11 in@)
Adjusting method Self–adjusting
Disc type Ventilated
Disc thickness 18 mm (0.71 in)
Disc effective diameter 269.2 mm (10.60 in)
E05RW005
PARKING BRAKE 5D–1
TROOPER
BRAKES
PARKING BRAKE SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 5D–1 Parking Brake Rear Cable . . . . . . . . . . . . . . . . 5D–5
General Description . . . . . . . . . . . . . . . . . . . . . 5D–1 Parking Brake Rear Cable and
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D–2 Associated Parts . . . . . . . . . . . . . . . . . . . . . . 5D–5
Parking Brake Lever and Front Cable . . . . . . 5D–3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D–5
Parking Brake Lever, Front Cable and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D–6
Associated Parts . . . . . . . . . . . . . . . . . . . . . . 5D–3 Inspection and Repair . . . . . . . . . . . . . . . . . . 5D–7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D–3 Parking Brake Adjustment . . . . . . . . . . . . . . . . 5D–7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D–4 Main Data and Specifications . . . . . . . . . . . . . 5D–8

Pulling up the parking brake lever by hand will set the
parking brake. Once pulled up, the lever is held by a
ratchet–type lock until it is released. The position of the
lever is transmitted through cable/lever systems to the
rear wheels. These parts are designed in order to obtain
sufficient braking force when parking on slopes. When the
parking brake is set, or when the ignition switch is in the
“ON” position, the brake warning light illuminates.
The rear wheel parking brake is a duo–servo brake
(mechanical inside expansion type) built into the rear disc
brake. Parking brake adjustment is made through the
adjusting hole bored through the back plate. Adjust the
parking brake lever stroke to six or seven notches. Refer
CAUTION: Always use the correct fastener in the to “Parking Brake Adjustment” in this Section.
systems.
5D–2 PARKING BRAKE
Operation
C05RW003
Legend (6) Parking Cable Guide

(1) Strut (7) Primary Shoe
(2) Fulcrum B (8) Parking Brake Cable Guide
(3) Parking Lever (9) Adjusting Hole Plug
(4) Secondary Shoe (10) Adjusting Screw Notch
(5) Adjusting Screw Notch (11) Shoe Expanding Direction
When pulled in the direction “A”, the parking lever presses

the secondary shoe against the brake drum using the
lever/shoe joint “B” as a fulcrum and pushes the strut in
the direction “C”. The strut ,in turn, presses the primary
shoe against the brake drum. Counter force “D” to the
primary shoe is transmitted again to the secondary shoe
through the fulcrum “B”. The secondary shoe contacts the
drum thereby producing braking effect. Clearance which
may result from worn parking brake shoe lining can be
adjusted by turning the adjusting screw. Refer to “Parking
Brake Adjustment” in this Section.
Parking Brake Lever and Front Cable

Parking Brake Lever, Front Cable and Associated Parts
311RW001
Legend (4) Equalizer

(1) Parking Brake Lever (5) Parking Brake Front Cable
(2) Bolt (6) Switch Connector
(3) Adjusting Nut
Removal
1. Remove adjusting nut (3).
2. Remove equalizer (4).
311RX001
(Refer to Section 10 “Body”.)
4. Remove bolts.
5. Disconnect switch connector.
6. Remove parking brake lever.
7. Remove parking brake front cable.
Installation
1. Install parking brake front cable.
2. Install parking brake lever and apply grease (BESCO
L–2 or equivalent) to front cable contact point.
3. Reconnect switch connector.
4. Install bolts and tighten the parking brake lever fixing
5. Install center console.
(Refer to Section 10 “Body”.)
6. Install equalizer.
7. Install adjusting nut and adjust the parking brake
lever. (See “Parking Brake Adjustment” in this
section.)
Parking Brake Rear Cable

Parking Brake Rear Cable and Associated Parts
311RW003
Legend (8) Caliper Assembly

(1) Adjust Nut (9) Rotor (Drum)
(2) Back Plate (10) Rear Wheels
(3) Bolt (11) Cable Fixing Bolt
(4) Holding Spring (12) Clip
(5) Return Spring; Upper (13) Clip
(6) Shoe Assembly (14) Clip
(7) Return Spring; Lower (15) Rear Cable
Removal 3. Remove caliper assembly, remove two bolts to

remove the caliper assembly from the support
1. Remove adjusting nut. bracket. (Refer to “Rear Disc Brakes in Disc Brakes”
2. Remove rear wheels. in Section 5C). Temporarily hang the caliper with a
wire in order to avoid stretching the brake hose.
4. Remove rotor (drum).
5. Remove clip (floor side).
6. Remove bolt.
8. Remove clip (frame side).
9. Remove clip (suspension side).
10. Remove holding spring.
11. Remove return spring; upper.
12. Remove return spring; lower.
13. Remove the brake shoe assembly. Then remove the
parking brake cable from the parking brake lever (1).
308RS002
4. Install return spring; lower.

5. Install return spring; upper and the parking brake
lever (3) side (secondary side) return spring must be
installed on the outer side (2) of the primary side
return spring.
308RW001
14. Remove cable fixing bolt.

15. Remove rear cable.
Installation
1. Install rear cable and apply grease (BESCO L–2 or
equivalent) to the connecting portion of the rear cable
and the equalizer.
2. Install cable fixing bolt and tighten the cable fixing bolt
3. Install shoe assembly and after installation of the
shoe and cable assembly, apply the special grease 308RW002
included in the repair kit to the portions indicated in the 6. Install holding spring.
illustration.
7. Install clip (suspension side) and tighten the bolt to
8. Install clip (frame side) and tighten the bolt to the
specified torque.
10. Install bolt and tighten the bolt to the specified torque.
11. Install clip (floor side) and tighten the bolt to the
specified torque.
12. Install rotor.
13. Install caliper assembly. 2. Adjustment of parking brake cable
14. Install rear wheels. a. Turn the equalizer nut so that the parking brake
15. Install adjusting nut and apply grease (BESCO L–2 or lever travels 6 or 7 notches when pulled up with a
equivalent) to front cable contact point. force of 30 kg (66 lb).
16. Tighten the adjusting nut to the specified torque and b. Make sure that there is no brake dragging and
to adjust the parking brake, refer to “Parking Brake tighten the cable lock nut.
Adjustment” in this section. Torque : 6 N·m (52 lb in)
Torque: 6 N·m (52 lb in) 3. Break–in of parking brake shoe
D When poor braking is felt, or just after replacement
Inspection and Repair of parking brake shoes, be sure to conduct the
break–in procedure by driving the vehicle as
Parking Brake Lining Inspection follows:
Check the shoe assemblies for wear by removing the a. Forward 50 km/h (30 mph) × 400 m (about 30
brake drum rotor. seconds) with a lever pull force of 15 kg (33 lb).
Replace the shoe assemblies if the lining thickness is less b. Backward 10 km/h (6 mph) × 50 m (about 18
than 1.0 mm (0.039 in). seconds) with a lever pull force of 15 kg (33 lb).
Minimum limit: 1.0 m (0.039 in) NOTE: Break–in procedures must be performed under
safe conditions and traffic rules.
D If the braking effect remains poor after the break–in,
wait for some time until parking brake shoe cools
down and repeat procedures a. and b. noted above.
D On completion of break–in, inspect the parking
brake lever stroke, and if the lever does not come
within the specified number of notches when pulled
up, readjust.
D Excessive break–in may cause premature wear of
the parking brake lining.
308RW003
Parking Brake Rotor (Drum) Inspection

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

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

Rear parking brake
Type Duo–servo
Lining Dimension 121.2 cm@ (18.79 in@)
Adjusting Method Manual adjusting
Rotor (Drum) Inside Diameter 210 mm (8.27 in)
Parking Brake Lever Stroke 6–7 notches
When pulled with a force of 30 kg (66 lb)
E05RW006
ENGINE MECHANICAL 6A–1
TROOPER
ENGINE
CONTENTS
Engine Mechanical . . . . . . . . . . . . . . . . . . . . . . 6A Driveability and Emissions . . . . . . . . . . . . . . . . 6E
Engine Cooling . . . . . . . . . . . . . . . . . . . . . . . . . 6B Engine Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . 6F
Engine Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . 6G
Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . . 6D1 Engine Speed Control System . . . . . . . . . . . . 6H
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . 6D2 Inducton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6J
Starting and Charging System . . . . . . . . . . . . 6D3
ENGINE MECHANICAL
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 6A–2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–38
General Description . . . . . . . . . . . . . . . . . . . . . 6A–3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–39
Engine Diagnosis . . . . . . . . . . . . . . . . . . . . . . . 6A–4 Crankshaft and Main Bearings . . . . . . . . . . . . 6A–40
Cylinder Head Cover LH . . . . . . . . . . . . . . . . . 6A–19 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–40
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–20 Rear Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–45
Cylinder Head Cover RH . . . . . . . . . . . . . . . . . 6A–21 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–45
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–21 Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . 6A–46
Common Chamber . . . . . . . . . . . . . . . . . . . . . . 6A–22 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–46
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–22 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–49
Exhaust Manifold LH . . . . . . . . . . . . . . . . . . . . . 6A–24 Cylinder Head and Associated Parts . . . . . 6A–49
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–24 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–50
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–24 Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–50
Exhaust Manifold RH . . . . . . . . . . . . . . . . . . . . 6A–25 Inspection and Repair . . . . . . . . . . . . . . . . . . 6A–50
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–25 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–51
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–25 Valve Spring, Oil Controller, Valve, Valve
Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . . . 6A–26 Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–53
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–26 Valve Spring, Oil Controller, Valve, Valve
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–26 Guide and Associated Parts . . . . . . . . . . . . 6A–53
Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–27 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–53
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–27 Inspection and Repair . . . . . . . . . . . . . . . . . . 6A–54
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–28 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–57
Valve Clearance Adjustments . . . . . . . . . . . . . 6A–58
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–32
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–32 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–60
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–32 Camshaft and Associated Parts . . . . . . . . . 6A–60
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–60
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–35
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–35
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–63
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–35
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–66
Valve Stem Oil Controller , Valve Spring and
Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–37 Crankshaft and Associated Parts . . . . . . . . 6A–66
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–37 Inspection and Repair . . . . . . . . . . . . . . . . . . 6A–67
Piston, Piston Ring and Connecting Rod . . . 6A–38
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–70
6A–2 ENGINE MECHANICAL
Piston and Connecting Rod . . . . . . . . . . . . . . . 6A–74 Cylinder Block and Associated Parts . . . . . 6A–81
Piston, Connecting Rod and Associate Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–81
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–74 Inspection and Repair . . . . . . . . . . . . . . . . . . 6A–82
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–74 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–83
Inspection and Repair . . . . . . . . . . . . . . . . . . 6A–75 Main Data and Specification . . . . . . . . . . . . . . 6A–86
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–79 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–92
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . 6A–81

systems.
General Description Cylinder Head

The cylinder head, made of aluminum alloy casting
Engine Cleanliness And Care employs a pent–roof type combustion chamber with a
An automobile engine is a combination of many spark plug in the center. The intake and exhaust valves
machined, honed, polished and lapped surfaces with are placed in V–type design. The ports are cross–flow
tolerances that are measured in the thousandths of a type.
millimeter (ten thousandths of an inch). Accordingly,
when any internal engine parts are serviced, care and Valve Train
cleanliness are important. Throughout this section, it Intake and exhaust camshaft on the both side of banks
should be understood that proper cleaning and protection are driven through an camshaft drive gear by timing belt.
of machined surfaces and friction areas is part of the The valves are operated by the camshaft and the valve
repair procedure. This is considered standard shop clearance is adjusted to select suitable thickness shim.
practice even if not specifically stated.
D A liberal coating of engine oil should be applied to all Intake Manifold
friction areas during assembly to protect and lubricate The intake manifold system is composed of the aluminum
the surfaces on initial operation. cast common chamber and intake manifold attached with
D Whenever valve train components, pistons, piston six fuel injectors.
rings, connecting rods, rod bearings, and crankshaft
journal bearings are removed for service, they should Exhaust Manifold
be retained in order.
The exhaust manifold is made of nodular cast iron.
D At the time of installation, they should be installed in
the same locations and with the same mating Pistons and Connecting Rods
surfaces as when removed.
Aluminum pistons are used after selecting the grade that
D Battery cables should be disconnected before any meets the cylinder bore diameter. Each piston has two
major work is performed on the engine. Failure to compression rings and one oil ring. The piston pin is made
disconnect cables may result in damage to wire of chromium steel is offset 1mm toward the thrust side,
harness or other electrical parts. and the thrust pressure of piston to the cylinder wall varies
D The six cylinders of this engine are identified by gradually as the piston travels. The connecting rods are
numbers; Right side cylinders 1, 3 and 5, Left side made of forged steel. The connecting rod bearings are
cylinders 2, 4 and 6, as counted from crankshaft graded for correct seze selection.
pulley side to flywheel side.
Crankshaft and Bearings
General Information on Engine Service The crankshaft is made of Ductile cast–iron. Pins and
The following information on engine service should be journals are graded for correct size selection for their
noted carefully, as it is important in preventing damage bearing.
and contributing to reliable engine performance:
D When raising or supporting the engine for any reason, Engine Lubrication
do not use a jack under the oil pan. Due to the small The oil discharged by a trochoid–type oil pump driven by
clearance between the oil pan and the oil pump the crankshaft is fed through full–flow oil filter and to the oil
strainer, jacking against the oil pan may cause gallery provided under the crankshaft bearing cap. The oil
damage to the oil pick–up unit. is then led to the crankshaft journals and cylinder head.
D The 12–volt electrical system is capable of damaging The crank pins are lubricated with oil from crankshaft
circuits. When performing any work where electrical journals through oil holes. Also, an oil jet is fed to each
terminals could possibly be grounded, the ground cylinder from crankshaft juornals on the connecting rod
cable of the battery should be disconnected at the for piston cleaning. The oil pan flange is dealed with liquid
battery. packing only; do not deform or damage the flange surface
D Any time the intake air duct or air cleaner is removed, during removal or installation.
the intake opening should be covered. This will
protect against accidental entrance of foreign
material into the cylinder which could cause extensive
damage when the engine is started.
Cylinder Block
The cylinder block is made of aluminum die–cast casting
for 75°V–type six cylinders. It has a rear plate integrated
structure and employs a deep skint. The cylinder liner is
cast and the liner inner diameter and crankshaft journal
diameter are classified into grades. The crankshaft is
supported by four bearings of which width of No.3 bearing
on the body side is different in order to support the thrust
bearing. The bearing cap is made of nodular cast iron and
each bearing cap uses four bolts and two side bolts.
Engine Diagnosis
Hard Starting
1. Starting Motor Does Not Turn Over
Troubleshooting Procedure
Turn on headlights and starter switch.
Headlights go out or dim Battery run down or under charged Recharge or replace battery
considerably
Terminals poorly connected Clean battery posts and terminals
and connect properly
Starting motor coil circuit shorted Overhaul or replace
Starting motor defective Overhaul or replace
2. Ignition Trouble — Starting Motor Turns Over But Engine Does Not Start
Spark Test
Disconnect an igniton coil from any spark plug. Connect
the spark plug tester J–26792 (ST–125), start the engine,
and check if a spark is generated in the spark plug tester.
Before starting the engine, make sure that the spark plug
tester is properly grounded. To avoid electrical shock, do
not touch the part where insulation of the igniton coil is
broken while the engine is running.
Spark jumps across gap Spark plug defective Clean, adjust spark gap or replace
Ignition timing incorrect Refer to Ignition System
Fuel not reaching fuel injector(s) or Refer to item 3 (Trouble in fuel
engine system)
Valve timing incorrect Adjust
Engine lacks compression Refer to item 4 (Engine lacks
compression)
No sparking takes place Ignition coil disconnected or broken Connect properly or replace
Electronic Ignition System with Replace
module
Poor connections in engine harness Correct
Powertrain Control Module cable Correct or replace
disconnected or defective
3. Trouble In Fuel System

Starting motor turns over and spark Fuel tank empty Fill
occurs but engine does not start
start.
Water in fuel system Clean
Fuel filter clogged Replace filter
Fuel pipe clogged Clean or replace
Fuel pump defective Replace
Fuel pump circuit open Correct or replace
Evaporative Emission Control Correct or replace
System circuit clogged
Multiport Fuel Injection System faulty Refer to “Electronic Fuel Injection”
section
4. Engine Lacks Compression

Engine lacks compression Spark plug loosely fitted or spark Tighten to specified torque or replace
plug gasket defective gasket
Valve timing incorrect Adjust
Cylinder head gasket defective Replace gasket
Valve incorrectly seated Lap valve
Valve stem seized Replace valve and valve guide
Valve spring weakened or broken Replace
Cylinder or piston rings worn Overhaul engine
Piston ring seized Overhaul engine.
Engine Compression Test Procedure

1. Start and run the engine until the engine reaches
normal operating temperature.
2. Turn the engine off.
3. Remove all the spark plugs.
4. Remove ignition coil fuse (15A) and disable the
ignition system.
5. Remove the fuel pump relay from the relay and fuse
box.
6. Engage the starter and check that the cranking speed
is approximately 300 rpm.
7. Install cylinder compression gauge into spark plug
hole.
8. With the throttle valve opened fully, keep the starter
engaged until the compression gage needle reaches
the maximum level. Note the reading.
9. Repeat the test with each cylinder.
If the compression pressure obtained falls below the
limit, engine overhaul is necessary.
Limit; 1000 kPa (145 psi)
Rough Engine Idling or Engine Stalling
Trouble in fuel injection system Throttle shutting off incomplete Correct or replace
Throttle position sensor circuit open Correct or replace
or shorted
Fuel injector circuits open or shorted Correct or replace
Fuel injectors damaged Replace
Fuel pump relay defective Replace
Mass Airflow Sensor circuit open or Correct or replace
poor connections
Mass Airflow Sensor defective Replace
Manifold Absolute Pressure Sensor Correct or replace
circuit open or poor connections
Manifold Absolute Pressure Sensor Replace
defective
Engine Coolant Temperature Sensor Correct or replace
Engine Coolant Temperature Sensor Replace
defective
Intake Air Temperature sensor circuit Correct or replace
open or poor connections
Intake Air Temperature sensor Replace
defective
Ion sensing module cable broken or Correct or replace
poor connections
Ion sensing module defective Replace
Vehicle Speed Sensor circuit open or Correct or replace
shorted
Vehicle Speed Sensor defective Replace
Trouble in emission control system Powertrain Control Module defective Replace
Exhaust Gas Recirculation Valve Correct or replace
Exhaust Gas Recirculation Valve Replace
faulty
Canister purge valve circuit open or Correct or replace
poor connections
Canister purge valve defective Replace
Evaporative Emission Canister Replace
Purge control valve defective
Trouble in ignition system Refer to “Hard Start”
Others Engine lacks compression Refer to “Hard Start”
Valve incorrectly seated Lap valve
Air Cleaner Filter clogged Replace filter element
Valve timing incorrect Readjust
Idle air control valve broken Replace
Fast idle solenoid defective Replace
Positive Crankcase Ventilation valve Replace
defective or clogged
Rough Engine Running
Engine misfires periodically Ignition coil layer shorted Replace
Spark plugs fouling Clean or install hotter type plug
Spark plug(s) insulator nose leaking Replace
Fuel injector(s) defective Replace
Powertrain control module faulty Replace
Engine knocks periodically Spark plugs running too hot Install colder type spark plugs
Powertrain control module faulty Replace
Ion sensing module faulty Refer or replace
Engine lacks power Spark plugs fouled Clean
Fuel injectors defective Replace
Mass Airflow Sensor or Intake Correct or replace
Airflow Sensor circuit defective
Manifold Absolute Pressure (MAP) Correct or replace
Sensor or Manifold Absolute
Pressure Sensor circuit defective
or Engine Coolant Temperature
Sensor circuit defective
Powertrain Control Module faulty Replace
Intake Air Temperature Sensor or Correct or replace
Intake Air Temperature Sensor
circuit defective
Throttle Position Sensor or Throttle Correct or replace
Position Sensor circuit defective
Ion sensing module or ION sensing Correct or replace
module circuits defective
Hesitation
Hesitation on acceleration Throttle Position Sensor adjustment Replace throttle valve assembly
incorrect
Throttle Position Sensor circuit open Correct or replace
or shorted
poor connections
Manifold Absolute Pressure (MAP) Correct or replace
Sensor circuit open or shorted
MAP Sensor defective Replace
Intake Air Temperature (IAT) Sensor Correct or replace
circuit open or shorted
Ion sensing module Circuit open or Correct or replace
poor connections
IAT Sensor defective Replace
Hesitation at high speeds Fuel tank strainer clogged Clean or replace
(Fuel pressure too low) Fuel pipe clogged Clean or replace
Fuel filter clogged Replace
Defective fuel pump system Check and replace
Fuel Pressure Control Valve leaking Replace
Hesitation at high speeds Power supply or ground circuit for Check and correct or replace
(Fuel injector not working normally) Multiport Fuel Injection System
shorted or open
Fuel Injector defective Replace
Cable of Multiport Fuel Injection Correct or replace
System circuit open or poor
connections

Hesitation at high speeds Powertrain Control Module defective Replace
Throttle Position Sensor cable Correct or replace
broken or poor connections
Throttle Position Sensor defective Replace
defective
poor connections
MAP Sensor cable broken or poor Correct or replace
connections
MAP Sensor defective Replace
IAT Sensor circuit open or poor Correct or replace
connections
IAT Sensor defective Replace
Ion sensing module circuit open or Correct or replace
poor connections
Throttle valve not fully opened Check and correct or replace
Air Cleaner Filter clogged Replace filter element
Power supply voltage too low Check and correct or replace
Engine Lacks Power
Trouble in fuel system Fuel Pressure Control Valve not Replace
working normally
Fuel injector clogged Clean or replace
Fuel pipe clogged Clean
Fuel filter clogged or fouled Replace
Fuel pump drive circuit not working Correct or replace
normally
Fuel tank not sufficiently breathing Clean or replace
due to clogged Evaporative
Emission Control System circuit
Water in fuel system Clean
Inferior quality fuel in fuel system Use fuel of specified octane rating
Powertrain Control Module supplied Correct circuit
poor voltage
Throttle Position Sensor cable Correct or replace
Mass Airflow Sensor not working Replace
normally
not working normally
Intake Air Temperature Sensor not Replace
working normally
defective
Powertrain Control Module defective Replace
Trouble in intake or exhaust system Air Cleaner Filter clogged Replace filter element
Air duct kinked or flattened Correct or replace
TWC defective Repair
Ignition failure ———— Refer to Hard Start Troubleshooting
Guide
Heat range of spark plug inadequate Install spark plugs of adequate heat
range
Ignition coil defective Replace

Engine overheating Level of Engine Coolant too low Replenish
Fan clutch defective Replace
Incorrect fan installed Replace
Thermostat defective Replace
Engine Coolant pump defective Correct or replace
Radiator clogged Clean or replace
Radiator filler cap defective Replace
Level of oil in engine crankcase too Change or replenish
low or wrong engine oil
Resistance in exhaust system Clean exhaust system or replace
increased defective parts
Throttle Position Sensor adjustment Replace with Throttle Valve ASM
incorrect
Throttle Position Sensor circuit open Correct or replace
or shorted
Cylinder head gasket damaged Replace
Engine overcooling Thermostat defective Replace (Use a thermostat set to
open at 82°C (180°F))
Engine lacks compression ———— Refer to Hard Start
Others Tire inflation pressure abnormal Adjust to recommended pressures
Brake drag Adjust
Clutch slipping Adjust or replace
Level of oil in engine crankcase too Correct level of engine oil
high
defective
Engine Noisy
Abnormal engine noise often consists of various noises
originating in rotating parts, sliding parts and other mov-
ing parts of the engine. It is, therefore, advisable to locate
the source of noise systematically.
Noise from crank journals or from Oil clearance increased due to worn Replace crank bearings and
crank bearings crank journals or crank bearings crankshaft or regrind crankshaft and
(Faulty
y crank journals
j and crank install the undersize bearing
bearings usually make dull noise that Crankshaft out of round Replace crank bearings and
becomes more evident when crankshaft or regrind crankshaft and
accelerating) install the undersize bearing
Crank bearing seized Crank bearing seized. Replace crank
bearings and crankshaft or regrind
crankshaft and install the undersize
bearing
Short out each spark plug in sequence using insulated
spark plug wire removers. Locate cylinder with defective
bearing by listening for abnormal noise that stops when
spark plug is shorted out.
Noise from connecting rods or from Bearing or crankshaft pin worn Replace connecting rod bearings
connecting rod bearings and crankshaft or regrind crankshaft
(Faulty
y connecting
g rods or pin and install the undersize bearing
connecting rod bearings usually Crankpin out of round Replace connecting rod bearings
make an abnormal noise slightly and crankshaft or regrind crankshaft
higher than the crank bearing noise, pin and install the undersize bearing
which becomes more evident when
engine
g is accelerated)) Connecting rod bent Correct or replace
Connecting rod bearing seized Replace connecting rod bearings
and crankshaft or regrind crankshaft
pin and install the undersize bearing
Abnormal noise stops when the spark plug on the cylinder
with defective part is shorted out.
Piston and cylinder noise Piston clearance increased due to Replace piston and cylinder body
(Faulty piston or cylinder usually cylinder wear
makes
k a combined
bi d mechanical
h i l
Piston seized Replace piston and cylinder body
thumpingg noise which increases
when engine is suddenly accelerated Piston ring broken Replace piston and cylinder body
but diminishes gradually as the
engine warms up) Piston defective Replace pistons and others
Short out each spark plug and listen for change in engine
noise.
Piston pin noise Piston pin or piston pin hole worn Replace piston, piston pin and
(Piston makes noise each time it connecting rod assy
goes up and down)
The slapping sound stops when spark plug on bad cylin-
der is shorted out.
Timing belt noise Timing belt tension is incorrect Replace pusher or adjust the tension
pulley or replace timing belt
Tensioner bearing defective Replace
Timing belt defective Replace
Timing pulley defective Replace
Timing belt comes in contact with Replace timing belt and timing cover
timing cover
Valve noise Valve clearance incorrect Replace adjusting shim
Valve and valve guide seized Replace valve and valve guide
Valve spring broken or weakened Replace
Valve seat off–positioned Correct
Camshaft worn out Replace
Crankshaft noise Crankshaft end play excessive Replace thrust bearing
(noise occurs when clutch is
engaged)
Engine knocking Preignition due to use of spark plugs Install Spark Plugs of adequate heat
of inadequate heat range range
Carbon deposits in combustion Clean
chambers
Fuel too low in octane rating Replace fuel
Wide Open Throttle enrichment Refer to Section 6E
system failure
Selection of transmission gear Caution operator of incorrect gear
incorrect selection
Engine overheating Refer to “Engine Lacks Power”
Others Water pump defective Replace
Drive belt slipping Replace auto tentioner or drive belt
Abnormal Combustion
Trouble in fuel system Fuel pressure control valve defective Replace
Fuel filter clogged Replace
Fuel pump clogged Clean or replace
Fuel tank or fuel pipe clogged Clean or replace
Fuel injector clogged Clean or replace
Fuel pump relay defective Replace
Power supply cable for fuel pump Reconnect, correct or replace
Mass Airflow (MAF) sensor circuit Correct or replace
open or defective
MAF Sensor defective Replace
Manifold Absolute Pressure Sensor Correct or replace
defective
Engine Coolant Temperature (ECT) Correct or replace
Sensor circuit open or shorted
ECT Sensor defective Replace
Throttle Position Sensor adjustment Readjust
incorrect
Throttle Position Sensor connector Reconnect
poor connections
Vehicle Speed Sensor cable poor Correct or replace
connections or defective
Vehicle Speed Sensor loosely fixed Fix tightly
Vehicle Speed Sensor in wrong Replace
contact or defective
Powertrain Control Module cable Correct or replace
poor connections or defective
Trouble in emission control system Heated Oxygen Sensor circuit open Correct or replace
Heated Oxygen Sensor defective Replace
Signal vacuum hose loosely fitted or Correct or replace
defective
EGR Valve circuit open or shorted Correct or replace
defective
ECT Sensor circuit open or shorted Correct or replace
Canister Purge Valve circuit open or Correct or replace
shorted
Canister Purge Valve defective Replace
ECT Sensor defective Replace
Positive Crankcase Ventilation Correct or replace
(PCV) valve and hose clogged
Evaporator system Refer to Section 6E
Trouble in ignition system ———— Refer to “Engine Lacks Power”

Trouble in cylinder head parts Carbon deposits in combustion Remove carbon
chamber
Carbon deposit on valve, valve seat Remove carbon
and valve guide
Engine Oil Consumption Excessive
Oil leaking Oil pan drain plug loose Retighten or replace gasket
Crankcase fixing bolts loosened Retighten
Oil pan setting bolts loosened Retighten
Oil pan gasket broken Replace gasket
Front cover retaining bolts loose or Retighten or replace gasket
gasket broken
Head cover fixing bolts loose or Retighten or replace gasket
gasket broken
Oil filter adapter cracked Replace
Oil filter attaching bolt loose or rubber Retighten or replace oil filter
gasket broken
Crankshaft front or rear oil seal Replace oil seal
defective
Oil pressure unit loose or broken Retighten or replace
Blow–by gas hose broken Replace hose
Positive Crankcase Ventilation Valve Clean
clogged
Engine/Transmission coupling failed Replace oil seal
Oil leaking into combustion Valve stem oil seal defective Replace
chambers due to poor
oor seal in valve
system Valve stem or valve guide worn Replace valve and valve guide
Oil leaking into combustion Cylinders and pistons worn Replace cylinder body assembly and
chambers due to poor seal in cylinder excessively pistons
parts
t Piston ring gaps incorrectly Correct
positioned
Piston rings set with wrong side up Correct
Piston ring sticking Replace cylinder body assembly and
pistons
Piston ring and ring groove worn Replace pistons and others
Return ports in oil rings clogged Clean piston and replace rings
Positive Crankcase Ventilation Positive Crankcase Ventilation Valve Clean
System malfunctioning clogged
Others Improper oil viscosity Use oil of recommended S.A.E.
viscosity
Continuous high speed driving Continuous high speed operation
and/or severe usage such as trailer and/or severe usage will normally
towing cause increased oil consumption
Fuel Consumption Excessive
Trouble in fuel system Mixture too rich or too lean due to Refer to “Abnormal Combustion”
trouble in fuel injection system
Fuel cut function does not work Refer to “Abnormal Combustion”
Trouble in ignition system Misfiring or abnormal combustion Refer to “Hard Start” or “Abnormal
due to trouble in ignition system Combustion”
Others Engine idle speed too high Reset Idle Air Control Valve
Fuel system leakage Correct or replace
Clutch slipping Correct
Brake drag Correct
Selection of transmission gear Caution operator of incorrect gear
incorrect selection
Excessive Exhaust Gas Refer to “Abnormal Combustion”
Recirculation flow due to trouble in
Exhaust Gas Recirculation system
Lubrication Problems
Oil pressure too low Wrong oil in use Replace with correct engine oil
Relief valve sticking Replace
Oil pump not operating properly Correct or replace
Oil pump strainer clogged Clean or replace strainer
Oil pump worn Replace
Oil pressure gauge defective Correct or replace
Crankshaft bearing or connecting Replace
rod bearing worn
Oil contamination Wrong oil in use Replace with correct engine oil
Oil filter clogged Replace oil filter
Cylinder head gasket damage Replace gasket
Burned gases leaking Replace piston and piston rings or
cylinder body assembly
Oil not reaching valve system Oil passage in cylinder head or Clean or correct
cylinder body clogged
Engine Oil Pressure Check

1. Check for dirt, gasoline or water in the engine oil. 4. Install an oil pressure gauge.
a. Check the viscosity of the oil. 5. Start the engine and allow the engine to reach normal
b. Change the oil if the viscosity is outside the operating temperature (About 80°C).
specified standard. 6. Measure the oil pressure.
c. Refer to the “Maintenance and Lubrication” section Oil pressure should be:
of this manual.
392–550 kPa (56.9–80.4 psi) at 3000 rpm.
2. Check the engine oil level.
7. Stop the engine.
The level should fall somewhere between the “ADD”
and the “FULL” marks on the oil level dipstick. 8. Remove the oil pressure gauge.
If the oil level does not reach the “ADD” mark on the 9. Install the oil pressure unit.
oil level dipstick, engine oil must be added. 10. Start the engine and check for leaks.
3. Remove the oil pressure unit.
Malfunction Indicator Lamp
The instrument panel “CHECK ENGINE” Malfunction In-
dicator Lamp (MIL) illuminates by self diagnostic system
when the system checks the starting of engine, or senses
malfunctions.
“CHECK ENGINE” MIL does not Bulb defective Replace
illuminate at the starting of engine
MIL circuit open Correct or replace
Command signal circuit to operate Correct or replace
self diagnostic system shorted
Engine Control Module (PCM) cable Correct or replace
loosely connected, disconnected or
defective
PCM defective Replace
“CHECK ENGINE” MIL illuminates, Deterioration of heated oxygen Replace
and stays on sensor internal element
Heated oxygen sensor connector Reconnect properly
terminal improper contact
Heated oxygen sensor lead wire Correct
shorted
Heated oxygen sensor circuit open Correct or replace
Deterioration of engine coolant Replace
temperature sensor internal element
Engine coolant temperature sensor Reconnect properly
connector terminal improper contact
Engine coolant temperature sensor Correct
lead wire shorted
Engine coolant temperature sensor Correct or replace
circuit open
Throttle position sensor open or Correct or replace
shorted circuits
Deterioration of crankshaft position Replace
sensor
Crankshaft position sensor circuit Correct or replace
open or shorted
Vehicle speed sensor circuit open Correct or replace
Manifold absolute pressure sensor Correct or replace
Intake air temperature sensor circuit Correct or replace
open or shorted
Fuel injector circuit open or shorted Correct or replace
PCM driver transistor defective Replace PCM
Malfunctioning of PCM RAM Replace PCM
(Random Access Memory) or ROM
(Read Only Memory)
Cylinder Head Cover LH

Removal 5. Ignition coil connector and ignition coil.
D Disconnect the three connectors from the ignition
1. Disconnect battery ground cable. coils.
2. Remove engine cover from the dowels on the
D Remove harness bracket bolt on cylinder head
common chamber.
cover.
D Remove fixing bolts on ignition coils.
F06RY001
3. Disconnect positive crankcase ventilation hose.

4. Remove ground cable fixing bolt on cylinder head 060RY022
cover. Legend
(1) Ignition Coil Connector
(2) Bolt
(3) Ignition Coil Assemblies
6. Disconnect fuel injector harness connector then

remove fuel injector harness bracket bolt.
7. Remove eight fixing bolts, then the cylinder head
cover.
010RW001
Installation
1. Install cylinder head cover.
D Clean the sealing surface of cylinder head and
cylinder head cover to remove oil and sealing
materials completely.
D Apply sealant (TB-1207B or equivalent) of bead
diameter 2-3 mm at eight place of arched area of
camshaft bearing cap on front and rear sides.
D The cylinder head cover must be installed with in 5
minutes after sealant application to prevent
hardning of sealant.
D Tighten bolts to the specified torque.
060RY022
Legend
(2) Bolt
(3) Ignition Coil Assembly
CAUTION: Ignition coil assembly #6 is different

from ignition coil assembly from #1 to #5. Ignition
coil assembly #6 is short type. So, note it when
installing ignition coil assembly of #6.
010RW008
2. Install fuel injection harness bracket and tighten bolt

3. Connect ignition coil connector and ignition coil, then
tighten bolt to the specified torque.
060RY00002
Legend
(1) Long Type Ignition Coil Assemblies (# 1 ∼ # 5)
(2) Short Type Ignition Coil Assembly (# 6)
4. Connect ground cable and tighten bolts to the

specified torque.
5. Install positive crankcase ventilation hose.
6. Install engine cover mating with the dowels.
Cylinder Head Cover RH

1. Disconnect battery ground cable. 1. Install cylinder head cover.
2. Remove engine cover from the dowele on the D Clean the sealing surface of cylinder head and
common chamber. cylinder head cover to remove oil and sealing
materials completely.
Apply sealant (TB-1207B or equivalent) bead
(diameter 2-3 mm) at eight places of arched areas
of camshaft bracket on front and rear sides.
D The cylinder head cover must be installed within 5
minutes after sealant application to prevent
premature hardening of sealant.
D Tighten bolts to the specified torque.
F06RY001
3. Disconnect ventilation hose from cylinder head cover.

4. Disconnect three ignition coil connectors from ignition
coils and remove harness bracket bolts on cylinder
head cover then remove ignition coil fixing bolts on
ignition coils and remove ignition coils.
5. Disconnect fuel injector harness connector then
remove fuel injector harness bracket bolt.
6. Remove eight fixing bolts then the cylinder head
cover.
014RW019
2. Tighten fuel injector harness bracket bolts to

specified torque then reconnect fuel injector harness
connector.
Torque : 7.8 N·m (5.7 lb ft)
3. Connect ignition coil connector and tighten ignition
coil fixing bolts to specified torque.
4. Connect ventilation hose to cylinder head.
5. Install engine cover mating with the dowels.
010RW002
Common Chamber
Removal
1. Disconnect battery ground cable.
2. Remove air cleaner duct assembly.
025RY002
Legend
(1) Common Chamber
(2) Throttle Valve Assembly
013RY00001
(3) Bolt
Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor Installation
(3) Air Cleaner Duct Assembly
1. Install common chamber and tighten bolts and nuts to
(4) Air Flow Sensor
3. Disconnect vacuum booster hose from common Torque :
chamber. Bolt : 25 N·m (18 lb ft)
4. Disconnect connector from manifold absolute Nut : 25 N·m (18 lb ft)
pressure sensor, ion sensing module, throttle position 2. Install fuel hose bracket and tighten bolts to specified
sensor, solenoid valve, electric vacuum sensing torque.
valve, and EGR valve.
5. Disconnect vacuum hose on canister VSV and
positive crankcase ventilation hose, fuel rail 3. Install exhaust gas recirculation valve assembly and
assembly with pressure control valve bracket. tighten bolt and nut to the specified torque.
6. Remove ventilation hose from throttle valve and Torque : 25 N·m (18 lb ft)
intake duct and remove water hose. 4. Install throttle body and tighten bolts to the specified
7. Remove the four throttle body fixing bolts. torque.
8. Remove exhaust gas recirculation valve assembly Torque : 25 N·m (18 lb ft)
fixing bolt and nut on common chamber and remove 5. Install ventilating hose to throttle valve and intake
EGR valve assembly. duct.
9. Remove two bolts from common chamber rear side 6. Connect vacuum hoses on canister VSV and positive
for remove fuel hose bracket. crankcase ventilation hose. Tighten bolts for fuel rail
10. Remove common chamber four bolts and four nuts assembly with pressure control valve bracket.
then remove the common chamber.
7. Connect each connector without fail.
8. Connect vacuum booster hose.
9. Connect the ion sensing module connectors as
shown in the illustration.
060RY00111
Legend
(1) Green Connector
(2) Blue Connector
(3) Identification Mark (6VE1 Engine Only)
10. Install air cleaner duct assembly.
013RY00001
Legend
(1) Positive Crankcase Ventilation Hose Connector
(2) Intake Air Temperature Sensor
(3) Air Cleaner Duct Assembly
(4) Mass Air Flow Sensor
Exhaust Manifold LH
1. Disconnect battery ground cable. 1. Install exhaust manifold and gasket and tighten
2. Remove transfer case skid plate. exhaust manifold fixing nuts to the specified torque
with new nuts.
3. Remove 3rd crossmember.
4. Disconnect Heated oxygen (O2) sensor connector. Torque: 52 N·m (38 lb ft)
5. Remove the three stud nuts from the front exhaust 2. Install heat protector.
pipe flange and two nuts from the rear exhaust pipe 3. Install exhaust front pipe’s three stud nuts and rear
flange. pipe’s two nuts to the specified torque.
Torque :
Stud nuts: 67 N·m (49 lb ft)
Nuts: 43 N·m (32 lb ft)
4. Set A/C compressor to normal position and tighten
two bolts to the specified torque.
5. Reconnect O2 sensor connectors.
6. Install 3rd crossmember.
7. Install transfer case skid plate.
035RX015
Legend
(1) O2 Sensors
(2) Exhaust Front Pipe LH
(3) Transfer Case Skid Plate
(4) 3rd Crossmember
6. Remove heat protector two fixing bolts and remove

unit.
7. Remove a bolt on engine LH side for air conditioner
(A/C) compressor bracket and loosen two bolts for
A/C compressor then move A/C compressor to front
side.
8. Remove exhaust manifold eight fixing nuts and
remove exhaust manifold from the engine.
Exhaust Manifold RH
Removal
035RX016
Legend (4) Front Propeller Shaft

(1) Exhaust Front Pipe RH (5) Transfer Case Skid Plate
(2) O2 Sensors (6) 3rd Crossmember
(3) Torsion Bar
1. Disconnect battery ground cable. Torque : 44 N·m (33 lb ft)

2. Remove transfer case skid plate. Tighten the bolt for EGR pipe bracket to specified
3. Remove 3rd crossmember. torque.
4. Remove torsion bar and front propeller shaft. Refer to Torque : 25 N·m (18 lb ft)
removal procedure in Front Suspension section. 2. Install heat protector
5. Disconnect front Heated oxygen (O2) sensor 3. Install front exhaust flange pipe and tighten three stud
connectors. nuts and rear two nuts to the specified torque.
6. Remove front exhaust flange pipe three stud nuts and
Torque:
two rear flange nuts then disconnect exhaust pipe.
Stud nuts: 67 N·m (49 lb ft)
7. Remove heat protector two fixing bolts and remove
unit. Nuts: 43 N·m (32 lb ft)
8. Remove exhaust manifolds eight fixing nuts and the 4. Reconnect O2 Sensor harness connector.
exhaust manifold. 5. Install the torsion bar and readjust the vehicle height.
Refer to installation and vehicle height adjustment
procedure for Front Suspension.
Installation 6. Install front propeller shaft.
1. Install exhaust manifold and tighten bolts to the Refer to installation procedue in Front suspension
specified torque. section.
Torque : 52 N·m (38 lb ft) 7. Install 3rd crossmember.
8. Install transfer case skid plate.
Crankshaft Pulley
Removal 4. Move serpentine belt tensioner to loose side using
wrench then remove serpentine belt.
2. Remove air cleaner assembly.
850RW001
Legend
013RY00001
Legend (2) Cooling Fan Pulley
(1) Positive Crankcase Ventilation Hose Connector (3) Tensioner
(2) Intake Air Temperature Sensor (4) Generator
(3) Air Cleaner Duct Assembly (5) Air Conditioner Compressor
(4) Mass Air Flow Sensor (6) Power Steering Oil Pump
(7) Idle Pulley
3. Remove radiator upper fan shroud from radiator. (8) Driver Belt
5. Remove cooling fan assembly four fixing nuts, then

the cooling fan assembly.
6. Remove crankshaft pulley assembly using J-8614-01
crankshaft holder, hold crankshaft pulley then
remove center bolt and pulley.
Installation
1. Install crankshaft pulley using J-8614-01 crankshaft
holder, hold the crankshaft pulley and tighten center
2. Install cooling fan assembly and tighten bolts/nuts to
Torque : 22 N·m (16 lb ft) for fan pulley and fan
bracket.
Torque : 10 N·m (88.5 lb in) for fan and clutch
assembly.
3. Move serpentine belt tensioner to loose side using
position.
4. Install radiator upper fan shroud.
5. Install air cleaner assembly.
Timing Belt
Removal 11. Remove right side timing belt cover then left side
timing belt cover.
1. Disconnect battery ground cable. 12. Remove lower timing belt cover
2. Remove air cleaner assembly. 13. Remove pusher.
3. Remove radiator upper fan shroud from radiator.
CAUTION: The pusher prevents air from entering
4. Move drive belt tensioner to loose side using wrench the oil chamber. Its rod must always be facing
then remove drive belt. upward.
850RW001
014RW011
Legend Legend
(1) Crankshaft Pulley (1) Up Side
(2) Cooling Fan Pulley (2) Down Side
(3) Tensioner (3) Direction For Installation
(4) Generator (4) Locking Pin
(6) Power Steering Oil Pump 14. Remove timing belt.
(7) Idle Pulley
CAUTION:
(8) Drive Belt
1. Do not bend or twist the belt, otherwise its core
5. Remove cooling fan assembly four nuts, then the could be damaged. The belt should not be bent at
cooling fan assembly. a radius less than 30 mm.
6. Remove cooling fan drive pulley assembly. 2. Do not allow oil or other chemical substances to
come in contact with the belt. They will shorten
7. Remove idle pulley assembly.
the life.
8. Remove serpentine belt tensioner assembly.
3. Do not attempt to pry or stretch the belt with a
9. Remove power steering pump assembly.
screw driver or any other tool during installation.
10. Remove crankshaft pulley assembly using J-8614-01
crankshaft holder, hold crankshaft pulley remove 4. Store timing belt in a cool and dark place. Never
center bolt, then the pulley. expose the belt direct sunlight or heat.
Installation 1. Install timing belt.

1. Align groove of crankshaft timing pulley with mark
NOTE: For correct belt installation, the letter on the belt on oil pump.
must be able to be read as viewed from the front of the Align the mark on the crankshaft timing pulley
vehicle. with alignment mark (white dotted line) on the tim-
ing belt.
Secure the belt with a double clip.
NOTE: When timing marks are aligned, No.2 piston will
be on Top Dead Center.
014RW005
Legend
(1) Crankshaft Timing Pulley
(2) RH Bank Camshaft Drive Gear Pulley
(3) Water Pump Pulley 014RW003
(4) Idle Pulley Legend

(5) LH Bank Camshaft Drive Gear Pulley (1) Alignment Mark on Oil Pump
(6) Tension Pulley (2) Groove on Crankshaft Timing Pulley
(7) Alignment Mark on Oil Pump. (3) Alignment Mark on Crankshaft Timing Pulley
(8) Alignment Mark on Timing Belt (4) Alignment Mark on Timing Belt
014RW006
Legend
(1) Timing Belt
(2) Engine Rotation Direction
(3) Cylinder Head Side
2. Align the marks on the camshaft drive gear NOTE: It is recommended for easy installation that the
pulleys with the corresponding alignment marks belt be secured with a double clip after it is installed to
on the cylinder head covers. each pulley.
014RW004 014RW009
Legend 5. Install crankshaft pulley temporarily and tighten

(1) Alignment Mark on Camshaft Drive Gear center bolt by hand (do not use a wrench).
Pulley Turn the crankshaft pulley clockwise to give some
(2) Alignment Mark on Cylinder Head Cover. belt slack between the crankshaft timing pulley
(3) Alignment Mark on Timing Belt (White Line) and the RH bank camshaft drive gear pulley.
2. Install pusher and tighten bolt to the specified torque.
3. Align the alignment mark (white line) on the timing 1. Install the pusher while pushing the tension pulley
belt with alignment mark on the RH bank to the belt.
camshaft drive gear pulley (on the left side as 2. Pull out pin from the pusher.
viewed from the front of the vehicle).
Secure the belt with a double clip. NOTE: When reusing the pusher, press the pusher with
approximately 100Kg to retract the rod, and insert a pin
(1.4 mm piano wire).
014RW008
4. Align the alignment mark (white line) on the timing

belt with the alignment mark on the LH bank
camshaft drive gear pulley.
When aligning the timing marks, use a wrench to
turn the camshaft drive gear pulley, then set the
timing mark between timing belt and camshaft
drive gear pulley.
Secure the belt with a double clip.
014RW011 020RW003
Legend Legend
(1) Up Side (1) Timing Belt Cover
(2) Down Side (2) Rubber Bushing
(3) Direction for Installation (3) Sealing Rubber
(4) Locking Pin (4) Cylinder Body
3. Remove double clips from timing belt pulleys. 4. Install crankshaft pulley using J-8614-01, hold the
Turn the crankshaft pulley clockwise by two turns. crankshaft pulley and tighten center bolt to the
specified torque.
3. Install timing belt cover.
Remove crankshaft pulley that was installed in step 5. Install fan pulley bracket and tighten fixing bolts to the
1 item 5. specified torque.
Tighten bolts to the specified torque. Torque : 22 N·m (16 lb ft)
Torque: 19 N·m (14 lb ft) 6. Install power steering pump assembly and tighten to
Torque :
M8 bolt : 22 N·m (16 lb ft)
M10 bolt : 46 N·m (34 lb ft)
7. Install cooling fan assembly and tighten bolts/nuts to
bracket.
assembly.
020RW004
Legend
(1) Timing Belt Cover RH
(2) Timing Belt Cover LH
(3) Timing Belt Cover Lower
8. Move drive belt tensioner to loose side using wrench,
then install drive belt to normal position.
850RW001
Legend
(3) Auto Tensioner
(4) Generator
(7) Idle Pulley
(8) Drive Belt
9. Install radiator upper fan shroud.

Camshaft
Removal
2. Remove crankshaft pulley.
D Refer to removal procedure for Crankshaft Pulley in
this manual.
3. Remove timing belt.
D Refer to removal procedure for Timing Belt in this
manual.
4. Remove cylinder head cover LH.
D Refer to removal procedure for Cylinder Head
Cover LH in this manual.
5. Remove cylinder head cover RH.
Cover RH in this manual.
6. Remove twenty fixing bolts from inlet and exhaust
camshaft bearing cap on one side bank, then
camshaft bearing caps. 014RW026
Legend
(1) Right Bank
(2) Left Bank
(3) Timing Mark on Retainer
Installation
1. Install camshaft drive gear assembly and tighten
three bolts to the specified torque.
2. Tighten bolt for camshaft drive gear assembly pulley
3. Tighten sub gear setting bolt.
1. Use the J–42686 gear spring lever to turn sub
gear to right direction until it aligns with the M5 bolt
014RW027 hole between camshaft driven gear and sub gear.
7. Remove camshaft assembly.
2. Tighten the M5 bolt to a suitable torque to prevent
8. Remove fixing bolt for camshaft drive gear pulley. the sub gear from moving.
9. Remove three fixing bolts from camshaft drive gear
retainer, then camshaft drive gear assembly.
014RW041 014RW023
4. Install camshaft assembly and camshaft bearing Legend

caps, tighten twenty bolts on one side bank to the (1) Right Bank Camshaft Drive Gear
specified torque.
(2) Left Bank Camshaft Drive Gear
1. Apply engine oil to camshaft journal and bearing (3) Timing Mark on Drive Gear
surface of camshaft bearing cap.
(4) Dowel Pin
2. Align timing mark on intake camshaft (one dot for
right bank, two dots for left bank) and exhaust
camshaft (one dot for right bank, two dots for left
bank) to timing mark on camshaft drive gear (one
dot).
014RW020
Legend
(1) Intake Camshaft Timing Gear for Right Bank
(2) Intake Camshaft Timing Gear for Left Bank
(3) Exhaust Camshaft Timing Gear
(4) Discrimination Mark
(LI: Left bank intake, RI: Right bank intake)
(LE: Left bank exhaust, RE: Right bank
exhaust)
014RW024
Legend (3) Alignment Mark on Camshaft Drive Gear

(1) Right Bank (4) Alignment Mark on Camshaft
(2) Left Bank (5) Alignment Mark on Retainer
3. Tighten twenty bolts on numerical order an one 5. Install cylinder head cover RH.
side bank as shown in the illustration. D Refer to installation procedure for CYLINDER
Torque : 10 N·m (89 lb in) HEAD COVER RH in this manual.
6. Install cylinder head cover LH.
D Refer to installation procedure for CYLINDER
HEAD COVER LH in this manual.
7. Install timing belt.
D Refer to installation procedure for TIMING BELT in
this manual.
8. Install crankshaft pulley.
D Refer to installation procedure for CRANKSHAFT
PULLEY in this manual.
014RW031
Cylinder Head
1. Remove engine hood. 1. Install cylinder head assembly to cylinder block.
2. Disconnect battery ground cable. A. Put cylinder head gasket on the cylinder block.
3. Drain radiator coolant. NOTE: There is discrimination mark “R” for right bank
4. Drain engine oil. and “L” for left bank on the cylinder head gasket as shown
5. Remove crankshaft pulley. in the illustration.
D Refer to removal procedure for Crankshaft Pulley in Do not reuse cylinder head gasket.
this manual.
manual.
7. Remove cylinder head cover LH.
8. Remove cylinder head cover RH.
9. Remove common chamber.
D Refer to removal procedure for Common Chamber
in this manual.
10. Remove cylinder head assembly.
A. Loosen head bolts in reverse of tightening
sequence.
B. Remove cylinder head assembly.
011RW005
B. Align dowel pin hole to dowel pin on the cylinder

block.
C. Position cylinder head on the cylinder block.
D. Tighten two bolts temporarily by hand to prevent
the cylinder head assembly from moving.
E. Using J-24239-01 cylinder head bolt wrench,
tighten bolts in numerical order as shown in the
illustration to the specified torque.
014RW028
Legend
(1) Cylinder Head
(2) Cylinder Head Bolt
(3) Camshaft
NOTE: Do not reuse cylinder head bolts.
Do not apply any lubricant to the cylinder head bolts.
Torque :
Temporary : 29 N·m (21 lb ft)
Final : 64 N·m (47 lb ft)
014RW029
2. Install common chamber.

D Refer to installation procedure for Common
Chamber in this manual.
3. Install cylinder head cover RH.
D Refer to installation procedure for Cylinder Head
4. Install cylinder head cover LH.
D Refer to installation procedure for Cylinder Head
D Refer to installation procedure for Timing Belt in this
manual.
D Refer to installation procedure for Crankshaft
Pulley in this manual.
Valve Stem Oil Controller , Valve Spring and Valve Guide

1. Disconnect battery ground cable. 1. Install valve guide using J–42899 valve guide
2. Drain engine oil. installer.
D Drain engine coolant. 2. Install oil controller using J–38537 oil controller
installer.
3. Install lower valve spring seat, valve spring and upper
D Refer to removal procedure for Cylinder Head in
valve spring seat then put split collars on the upper
this manual.
spring seat, using J–8062 valve spring compressor
4. Remove camshaft. and J–42898 valve spring compressor adapter to
D Refer to removal procedure for Camshaft in this install the split collars.
manual.
5. Remove tappets with shim.
NOTE: Do not damage shim surface.
6. Remove valve springs using J–8062 valve spring
compressor and J–42898 valve spring compressor
adapter then remove upper valve spring seat and
lower seat.
014RW042
4. Install tappet with shim.

5. Install camshaft assembly.
D Refer to installation procedure for Camshaft in this
manual.
6. Install cylinder head assembly.
D Refer to installation procedure for Cylinder Head in
014RW042 this manual.
7. Remove oil controller using J–37281 oil controller 7. Fill engine oil until full level.
remover, remove each valve stem oil controller. 8. Fill engine coolant.
8. Remove valve guide using J–37985 valve guide
replacer.
Piston, Piston Ring and Connecting Rod

Removal
F06RW011
Legend (4) Oil Strainer

(1) Cylinder Head (5) Oil Gallery
(2) Crankcase with Oil Pan (6) Piston with Connecting Rod Assembly
(3) Oil Pipe
1. Remove cylinder head assembly. 2. Remove crankcase with Oil Pan.

D Refer to removal procedure for Cylinder Head in D Refer to removal procedure for Oil Pan and
this manual. Crankcase in this manual.
3. Remove oil strainer fixing bolts, remove oil strainer
assembly with O-ring.
015RW003
Legend
050RW002 (1) Piston Front Mark
Legend (2) Piston Grade
(1) Oil Pump (3) Connecting Rod Front Mark
(2) Oil Strainer
(3) Oil Gallery 2. Install oil gallery and tighten the bolts in two steps, in
(4) From Oil Filter the order shown in illustration.
(5) To Oil Filter Torque :
1st step : 29 N·m (21 lb ft)
4. Remove three fixing bolts, oil pipe with O-ring. 2nd step : 55°–65°
5. Remove eight fixing bolts, oil gallery.
6. Remove piston with connecting rod assembly.
(before removing the bearing cap, remove carbon on
the top of cylinder bore and push piston with
connecting rod out from the top of cylinder bore.)
Installation
1. Install piston with connecting rod assembly.
D Apply engine oil to cylinder bore, connecting rod
bearing and crank pin.
When installing the piston, its front mark must face
the engine front side.
D The bearing cap number must be the same as
connecting rod number.
D Apply engine oil to the thread and seating surface of
each nut.
D Tighten nuts to the specified torque. 051RS009
Torque : 54 N·m (40 lb ft) 3. Install oil pipe with O-ring.

D After tightening the nuts, make sure that the Torque : 10 N·m (89 lb in)
crankshaft rotates smoothly. 4. Install oil strainer assembly with O-ring.
NOTE: Do not apply engine oil to the bearing back faces Torque : 25 N·m (18 lb ft)
and connecting rod bearing fitting surfaces. 5. Install crankcase with Oil Pan.
D Refer to installation procedure for Oil Pan and
Crankcase in this manual.
6. Install cylinder head assembly.
D Refer to installation procedure for Cylinder Head in
this manual.
Crankshaft and Main Bearings

Removal
F06RY002
Legend (8) Oil Pump Assembly

(1) Engine Assembly (9) Cylinder Body Side Bolt
(2) Crankshaft Pulley (10) Oil Gallery
(3) Timing Belt Cover (11) Flywheel
(4) Timing Belt (12) Rear Oil Seal Retainer
(5) Crankcase with Oil Pan (13) Connecting Rod Cap
(6) Oil Pipe (14) Crankshaft Main Bearing Cap
(7) Oil Strainer (15) Crankshaft and Main Bearing
1. Remove engine assembly. 3. Remove oil pan and crankcase.

D Refer to removal procedure for Engine Assembly in D Refer to removal procedure for Oil Pan and
this manual. Crankcase in this manual.
2. Remove timing belt. 4. Remove oil pipe with O-ring.
D Refer to removal procedure for Timing Belt in this 5. Remove oil strainer assembly with O-ring.
manual.
6. Remove oil pump assembly.
D Refer to removal procedure for Oil Pump in this
manual.
7. Remove cylinder body side bolts.
8. Remove oil gallery.
9. Remove flywheel.
10. Remove rear oil seal retainer.
D Refer to removal procedure for Rear Oil Seal in this
manual.
11. Remove connecting rod caps.
12. Remove crankshaft main bearing caps.
13. Remove crankshaft and main bearings.
Installation
1. Install crankshaft and main bearings.
D Install main bearing in the cylinder block and main
bearing cap respectively. 015RS013
Apply new engine oil to upper and lower main 2. Install crankshaft main bearing caps.
bearings. D Apply engine oil to the thread and seating surface of
each bearing cap fixing bolt.
NOTE:
NOTE:
D Do not apply engine oil to the bearing back faces.
D Do not apply engine oil to the bearing back faces.
D Make sure that main bearings are in correct position.
D Install bearing caps, starting with cylinder block front
D Install crankshaft with care. side.
D Apply engine oil to the thrust washer. D Tighten main bearing fixing bolts to the specified
D Install thrust washer on No.3 journal. torque.
D Oil grooves in thrust washer must face the Torque : 39 N·m (29 lb ft)
crankshaft.
D After tightening the bolts, make sure that the
crankshaft rotates smoothly.
3. Install connecting rod caps.
D The cap number must be same as connecting rod
number.
D Apply engine oil to the thread and seating surface of
each nut.
D Tighten nuts to the specified torque.
D After tightening the nuts, make sure that the
4. Install rear oil seal retainer.
D Remove oil on cylinder block and retainer fitting
surface.
D Apply sealant (TB1207B or equivalent) to retainer
fitting surface as shown in illustration.
015RS012
D The oil seal retainer must be installed within 5 D Tighten fixing bolts to the specified torque.
minutes after sealant application before the sealant Torque : 54 N·m (40 lb ft)
hardens.
015RS018
015RW002
6. Install oil gallery.
Legend D Clean contact surface of oil gallery and main
(1) Around Bolt Holes bearing cap.
(2) Around Dowel Pin Apply engine oil to oil gallery fixing bolts and tighten
the bolts in two steps, in the order shown in
D Apply engine oil to oil seal lip and align a dowel pin illustration.
hole in the cylinder block with that in the retainer. Torque :
D Tighten retainer fixing bolts to the specified torque. 1st step : 29 N·m (21 lb ft)
Torque : 18 N·m (13 lb ft) 2nd step : 55°–65°
7. Install cylinder body side bolts and tighten bolts in
order to the specified torque.
NOTE: Do not apply the oil to the bolts.
015RW001
5. Install flywheel.
D Clean tapped holes in the crankshaft.
D Remove oil on crankshaft and flywheel fitting
surface. 012RS007
NOTE: 8. Install oil pump assembly.

D Do not reuse the bolts. D Remove oil on cylinder block and oil pump mounting
surface.
D Do not apply oil or thread lock to the bolts.
D Apply sealant (TB1207B or equivalent) to the oil 11. Install crankcase.
pump mounting surface. D Remove oil on crankcase mounting surface and dry
D The oil pump assembly must be installed within 5 the surface.
minutes after sealant application before the sealant D Properly apply a 4.5 mm (0.7 in) wide bead of
hardens. sealant (TB1207C or equivalent) to the crankcase
D Apply engine oil to oil seal lip. mounting surface. The bead must be continuous.
D Install oil pump in the cylinder block and tighten D The crankcase must be installed within 5 minutes
fixing bolts to the specified torque. after sealant application before the sealant
hardens.
D Tighten fixing bolts to the specified torque.
051RW002
Legend
(1) Around Bolt Holes 013RW010
(2) Around Dowel Pin
013RW004
12. Install oil pan

051RW001
D Remove oil on oil pan mounting surface and dry the
9. Install oil strainer with O-ring, tighten to the specified surface.
torque. D Properly apply a 4.5 mm (0.7 in) wide bead of
Torque : 25 N·m (18 lb ft) sealant (TB1207C or equivalent) to the oil pan
mounting surface. The bead must be continuous.
10. Install oil pipe with O-ring, tighten fixing bolts to the
specified torque. D The oil pan must be installed within 5 minutes after
sealant application to prevent premature hardening
Torque : 25 N·m (18 lb ft) of sealant.
013RW003
013RW002

manual.
14. Install engine assembly.
D Refer to installation procedure for Engine in this
manual.
Rear Oil Seal

Removal
1. Remove transmission assembly.
D Refer to removal procedure for Transmission
section in this manual.
2. Remove flywheel.
3. Remove rear oil seal using a seal remover.
NOTE: Take care not to damage the crankshaft or oil seal
retainer when removing oil seal.
Installation
1. Apply engine oil to oil seal lip and install oil seal using
J-39201.
015RS018
3. Install transmission.
D See Transmission section in this manual.
CAUTION: When assembling the engine and
transmission, confirm that dowels have been
mounted in the specified positions at the engine
side.
NOTE: Take care that dowel positions are different
between the manual transmission and the automatic
transmission.
Otherwise, the transmission may be damaged.
015RS017
2. Install flywheel.
D Clean tapped holes in the crankshaft.
D Remove oil on the crankshaft and flywheel
mounting surface.
NOTE: Do not reuse the bolts and do not apply oil or
thread lock to the bolts.
012RS009
Engine Assembly
Removal
035RY00001
1. Disconnect battery ground and positive cable. 23. Move drive belt tensioner to loose side using wrench
2. Remove battery. then remove drive belt.
3. Make alignment mark on the engine hood and hinges 24. Remove power steering pump fixing bolts, then
before removal in order to return the hood to original power steering pump. Place the power steering pump
position exactly. along with piping on the body side.
4. Remove engine hood. 25. Remove air conditioning compressor fixing bolts from
bracket and place the compressor along with piping
5. Drain radiator coolant.
on the body side.
6. Disconnect ion sensing module harness connectors,
26. Remove four O2 sensor harness connectors (two
and manifold absolute pressure sensor harness
each bank) from exhaust front pipe.
connectors from sensors on common chamber.
27. Remove three exhaust pipe fixing nuts from each
7. Disconnect throttle position sensor harness
bank.
connectors from throttle body.
28. Remove two exhaust pipe fixing nuts from each
8. Disconnect air duct with air cleaner cover.
exhaust pipe, then move exhaust pipe to rear side of
9. Remove air cleaner assembly. vehicle.
10. Disconnect canister vacuum hose. 29. Remove flywheel dust covers.
11. Disconnect vacuum booster hose. 30. Disconnect two heater hoses from engine.
12. Disconnect three engine harness connectors. 31. Disconnect fuel hoses from right side of transmission.
13. Disconnect harness connector to transmission (left
CAUTION: Plug fuel pipes on engine side and fuel
front side of engine compartment), disconnect shift
hoses from fuel tank.
on the fly harness connector from front side of front
axle and remove transmission harness bracket from 32. Remove transmission assembly. Refer to
engine left side. Transmission section in this manual.
14. Disconnect ground cable between engine and frame. 33. Support the engine by engine hoist.
15. Disconnect bonding cable connector on the back of 34. Remove two left side engine mount fixing bolts from
right dash panel. engine mount on chassis side.
16. Disconnect bonding cable terminal on the left bank. 35. Remove two right side engine mount fixing bolts from
engine mount on chassis side.
17. Disconnect starter harness connector from starter.
36. Remove engine assembly.
18. Disconnect generator harness connector from
generator.
19. Disconnect coolant reserve tank hose from radiator.
20. Remove radiator upper and lower hoses.
21. Remove upper fan shroud.
22. Remove cooling fan assembly four fixing nuts, then
the cooling fan assembly.
Installation
CAUTION: When assembling the engine and
transmission, confirm that dowels have been
mounted in the specified positions at the engine
side.
NOTE: Take care that dowel positions are different
between the manual transmission and the automatic
transmission.
If the engine is assembled in the condition that the dowels
have not been mounted in the specified positions, the
transmission may be damaged the transmission.
035RW005
Legend
(1) Exhaust Front Pipe RH
(2) O2 Sensor
012RS009
1. Install engine assembly. Tighten engine mount fixing

bolts to frame to the specified torque.
2. Reconnect fuel hose to fuel pipe on engine.
3. Install transmission assembly. Refer to Transmission
section in this manual.
4. Reconnect two heater hoses to engine.
5. Install flywheel dust covers.
6. Install exhaust pipe and temporally tighten two (each
bank) rear exhaust flange nuts then tighten three stud 035RW016
nuts (each bank) between exhaust manifold and

exhaust pipe, finally tighten rear side nuts to the Legend
specified torque. (1) O2 Sensor
(2) Exhaust Front Pipe LH
Torque:
Nuts: 43 N·m (32 lb ft) 7. Reconnect O2 sensor connector.
Stud nuts: 67 N·m (49 lb ft) 8. Install cooling fan assembly and tighten bolts/nuts to
bracket.
assembly.
9. Install air conditioner compressor to engine and
tighten to the specified torque.
6VE1
Torque :
M8 bolts : 22 N·m (16 lb ft) 26. Reconnect throttle position sensor harness
M10 bolts : 43 N·m (32 lb ft) connector.
10. Install power steering pump, tighten fixing bolt to the
specified torque.
Torque :
M8 bolts : 22N·m (16 lb ft)
M10 bolts : 46 N·m (34 lb ft)
025RY001
Legend
(1) Throttle Position Sensor Connector
(2) Throttle Valve Assembly
27. Reconnect manifold absolute pressure sensor

harness connectors.
28. Reconnect ion sensing module connectors as shown
850RW001
in the illustration.
Legend
(3) Tensioner
(4) Generator
(7) Idle Pulley
(8) Drive Belt
12. Install upper fan shroud.

13. Reconnect radiator upper and lower hoses.
14. Reconnect coolant reserve tank hose to radiator.
15. Reconnect generator harness connector.
16. Reconnect starter harness connector.
17. Reconnect bonding cable terminal on left bank
18. Reconnect bonding cable terminal on the back of right
dash panel. 060RY00111
19. Reconnect ground cable between engine and Legend

chassis.
(1) Green Connector
20. Reconnect harness connector to transmission and (2) Blue Connector
install transmission harness bracket on engine left
side. (3) Identification Mark (6VE1 Engine Only)
21. Reconnect three engine harness connectors. 29. Install engine hood to the original position.
22. Reconnect vacuum booster hose. D Refer to installation procedure for Body section in
23. Reconnect canister vacuum hose. this manual.
25. Reconnect air duct.
Cylinder Head
Cylinder Head and Associated Parts
011RW008
Legend (8) Camshaft Intake

(1) Spark Plug (9) Retainer Fixing Bolt
(2) Cylinder Head Bolt (10) Retainer Assembly
(3) Camshaft Drive Gear Pulley Fixing Bolt (11) Tappet with Shim
(4) Camshaft Drive Gear Pulley (12) Split Collar
(5) Camshaft Bearing Cap Fixing Bolt (13) Valve Spring and Spring Upper Seat
(6) Camshaft Bearing Cap (14) Valve
(7) Camshaft Exhaust
Disassembly Inspection and Repair

NOTE: 1. Cylinder head gasket and mating surfaces for leaks,
corrosion and blow–by. If the gasket has failed,
D During disassembly, be sure that the valve train
determine the cause.
components are kept together and identified so that
they can be reinstalled in their original locations. – Insufficient torque on head bolts.
D Before removing the cylinder head from the engine – Improper installation
and before disassembling the valve mechanism, – Loose or warped cylinder head
perform a compression test and note the results. – Missing dowel pins
1. Remove camshaft drive gear pulley fixing bolt (3), – Warped case surface
then pulley (4). 2. Cylinder head for cracks, especially between valve
2. Remove camshaft bearing cap fixing bolt (5), seats and in the exhaust ports.
camshaft bearing cap (6), then camshaft exhaust (7), 3. Cylinder head deck for corrosion, sand particles in
and intake side (8). head and porosity.
3. Remove tappet with shim (11).
CAUTION:
4. Use the J–8062 valve spring compressor and
J–42898 valve spring compressor adapter to remove D Do not attempt to weld the cylinder head. Replace
the split collar (12), valve spring with upper seat (13) it.
and valve (14). D Do not reuse cylinder head bolts.
4. Cylinder head deck, common chamber and exhaust
manifold mating surfaces for flatness. These
surfaces may be reconditioned by milling. If the
surfaces are “out of flat” by more than specification,
the surface should be ground to within specifications.
Replace the head if it requires machining beyond the
repairable limit.
Head surface and manifold surface
Standard: 0.05 mm (0.002 in) or less
Warpage limit: 0.2 mm (0.0079 in)
Maximum Repairable limit: 0.2 mm (0.0079 in)
Head height
Standard height : 133.2 mm (5.2441 in)
Warpage limit : 0.2 mm (0.0079 in)
Maximum Repairable limit : 133.0 mm (5.2362 in)
014RW042
5. Remove spark plug (1).

CAUTION: Do not remove the spark plugs when the
head and plugs are hot. Clean dirt and debris from
spark plug recess areas before removal.
Clean
Cylinder head
Carefully remove all varnish, soot and carbon from the
bare metal. Do not use a motorized wire brush on any
gasket sealing surface.
011RW019
5. Water jacket sealing plugs seating surfaces.

Reassembly
1. Install Spark plug and tighten all the spark plugs to
specified torque.
1. Use J–(42686 gear spring lever) to turn sub gear
to right direction until the M5 bolt aligns with the
hole between camshaft driven gear and sub gear.
2. Tighten the M5 bolt to a suitable torque to prevent
the sub gear from moving .
014RW020
Legend
(4) Discrimination Mark
LI: Left Bank Intake
RI: Right Bank Intake
LE: Left Bank Exhaust
RE: Right Bank Exhaust
014RW025

three bolts to the specified torque.
Torque: 10 N·m (7.4 lb ft)
4. Install camshaft assembly and camshaft bearing cap,
tighten twenty bolts on one side bank to the specified
torque.
1. Apply engine oil to camshaft journal and bearing
dot).
014RW023
Legend
(1) Right Bank Camshaft Drive Gear
(3) Timing Mark on Drive Gear
(4) Dowel Pin
014RW024

3. Tighten twenty bolts in numerical order on one

side bank as shown in the illustration.
014RW031
5. Tighten bolt for camshaft drive gear assembly pulley

Valve Spring, Oil Controller, Valve, Valve Guide

Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts
014RW039
Legend (7) Spring Upper Seat

(1) Camshaft Bearing Cap Fixing Bolts (8) Valve Spring
(2) Camshaft Assembly Inlet (9) Oil Controller
(3) Camshaft Assembly Exhaust (10) Spring Lower Seat
(4) Shim (11) Valve Guide
(5) Tappet (12) Valve
(6) Split Collar
Disassembly 3. Remove camshaft assembly (Exhaust side).

4. Remove shim (4) and tappet (5).
1. Remove camshaft bearing cap fixing bolts (1).
2. Remove camshaft assembly (intake).
5. Use J–8062 valve spring compressor and J–42898 2. Measure the valve spring squareness with a steel
valve spring compressor adapter to remove split square and replace the valve springs if the measured
collar. value exceeds the specified limit.
Limit : 2 mm (0.0787 in)
014RW042
6. Remove valve spring.

014RS005
7. Remove valve. 3. Using a spring tester to compress the springs to the

8. Remove oil controller and spring lower seat. installed height, measure the compressed spring
9. Remove the valve guide using the J–42899 valve tension, and replace the springs if the measured
guide replacer. tension is below the specified limit.
At installed height: 35.0 mm (1.38 in)
Inspection and Repair Standard: 196 N (44 lb)
Limit: Less than 181 N (41 lb)
Valve Spring
CAUTION: Visually inspect the valve springs and
replace them if damage or abnormal wear is evident.
1. Measure the free height of the springs. The springs
must be replaced if the free height is below the
specified limit.
Limit : 43.6 mm (1.7165 in)
014RS006
Valve Guide
CAUTION: Take care not to damage the valve seat
contact surface, when removing carbon adhering to
the valve head. Carefully inspect the valve stem for
scratchs or abnormal wear. If these conditions are
present, the valve and the valve guide must be
replaced as a set.
014RS004
1. Measure the valve stem diameter with a micrometer.
If the valve stem diameter is less than the specified
limit, the valve and the valve guide must be replaced
as a set.
Diameter of Valve Stem
Intake
Standard : 5.977 mm–5.959 mm
(0.2353 in–0.2346 in)
Limit : 5.90 mm (0.2323 in)
Exhaust
(0.2343 in–0.2350 in)
Limit : 5.90 mm (0.2323 in)
014RS008
2. Apply engine oil to the outside of the valve guide.

Using valve guide replacer J–42899, drive in a new
valve guide from the camshaft side, and check the
valve guide height.
Valve guide upper end height: 13.0 mm (0.5118
in)
(Measured from the cylinder head upper face)
014RS007
2. Measure the inside diameter of the valve guide with a

micrometer. Subtract the measured outer diameter of
the valve stem from the measured inner diameter of
the valve guide. If the value exceeds the specified
limit, the valve and the valve guide must be replaced
as a set.
Inside Diameter of the Vale Guide
Inlet clearance
(0.0009 in–0.0002 in)
Limit : 0.20 mm (0.00787 in)
014RW046
Exhaust clearance
3. Check the clearance. If the clearance is less than the
Standard : 0.030 mm–0.063 mm specified value, ream the inside diameter of valve
(0.0012 in–0.0025 in) guide. Using a sharp 6 mm reamer, ream the valve
Limit : 0.20 mm (0.00787 in) guide to obtain the specified clearance.
Valve Guide Replacement Valve Seat

1. Using Valve guide replacer: J–42899, drive out the 1. Measure the protrusion of the valve stem when a new
valve guide from the combustion chamber side. valve is installed in the cylinder head. If the protrusion
of the valve stem exceeds the limit, replace the valve
seat insert or the cylinder head assembly.
Protrusion of valve stem
Intake
Limit: 39.47 mm (1.5539 in) 2. If the measured value exceeds the limit, replace
Exhaust valve, valve guide and valve seat as a set.
Standard: 39.30 mm (1.5472 in) Valve contact surface angle: 45°
Limit: 39.45 mm (1.5531 in)
014RS012
2. Measure the valve seat contact width. Make the

014RW047
Valve Seat Insert Correction
necessary corrections if the seat contact surface is 1. Remove the carbon from the valve seat insert
damaged or rough or if the contact width wear surface.
exceeds the limit. 2. Use a valve cutter to minimize scratches and other
Valve seat contact width rough areas. This will bring the contact width back to
Standard: 1.1 mm (0.0433 in) the standard value. Remove only the scratches and
rough areas. Do not cut away too much. Take care not
Limit: 1.7 mm (0.0669 in) to cut away unblemished areas of the valve seat
surface.
Valve seat angle degree: 90°
014RS011
Contact Surface Angle on Valve Seat on

Valve 014RW059
3. Apply abrasive compound to the valve seat insert

1. Measure contact surface angle on valve seat. surface.
4. Insert the valve into the valve guide.
5. Turn the valve while lapping it to fit the valve seat
insert.
6. Check that the valve contact width is correct.
7. Check that the valve seat insert surface is in contact 7. After insertion, use a seat grinder to grind finish the
with the entire circumference of the valve. seating face. Carefully note the seating angle, the
contact width, and the depression.
8. Lap the valve and the seat.
Reassembly
1. Install valve guide (1) to cylinder head. Apply engine
oil to the outside of the valve guide. Using valve guide
replacer J–42899, drive in a new valve guide from the
camshaft side.
2. Install oil controller (3) and spring lower seat (2).
Using oil controller replacer J–37281, drive in a new
oil controller.
014RS014
Valve Seat Insert Replacement

1. Arc weld the rod at several points. Be careful not to
damage the aluminum section.
2. Allow the rod to cool for a few minutes. This will cause
the valve seat to shrink.
3. Strike the rod and pull it out.
014RW058
3. Install valve to valve guide. Before install valve guide

apply engine oil to the outside of the valve stem.
4. Install valve spring to cylinder head. Attach the valve
spring to the lower spring seat. The painted area of
the valve spring should be facing downward.
014RS015
4. Carefully clean the valve seat press–fit section on the

cylinder head side.
5. Heat the press–fit section with steam or some other
means to cause expansion. Cool the valve seat with
dry ice or some other means.
6. Insert the press–fit section into the valve seat
horizontally.
Standard fitting interference: 0.14 mm–0.09 mm
(0.0055 in–0.0035 in) 014RS020
5. Install lower valve spring seat, valve spring and upper Valve Clearance Adjustments
valve spring seat then put split collars on the upper
spring seat, using the J–8062 valve spring NOTE: To adjust valve clearance, apply engine oil to the
compressor and J–42898 valve spring compressor cam as well as to the adjusting shim (2) with the cylinder
adapter to install the split collars. head built on the cylinder block, give a few turns to the
camshaft by means of timing pulley tightening bolt, and
measure valve clearance when the nose of cam is just
opposite to maximum cam lift (1) as shown in illistration
below.
014RW042
6. Install tappet with shim.

7. Install camshaft assembly.
D Refer to installation procedure for Camshaft in this
manual. 014RW081
Legend
(1) Cam
(2) Shim
(3) Tappet
Valve Clearance Standard Value (cold)

Intake: 0.23 mm–0.33 mm
(0.0091 in–0.0130 in)
Exhaust: 0.25 mm–0.35 mm
(0.0098 in–0.0138 in)
Selection of Adjusting Shim

Shim to be selected = (Thickness of removed shim) +
(Valve clearance measurement – Standard valve)
Based on the above formula, the best suited shim should
be selected from 41 sorts of shim (differently thick at
0.02mm (0.0008 in) intervals from 2.40mm (0.0945 in)
through 3.2mm (0.1260 in) thick). Install the shim and
check valve clearance.
Replacement of Shim
Let the cam push down the edge of tappet by using
J–42689 valve clearance adjusting tool and push out the
shim with a flat blade screw driver as shown in illustrations
below.
014RW084
014RW082
014RW083
Camshaft
Camshaft and Associated Parts
014RW040
Legend (6) Camshaft Drive Gear Pulley

(1) Camshaft Bearing Cap Fixing Bolt (7) Retainer Fixing Bolt
(2) Camshaft Bearing Cap (8) Retainer
(3) Camshaft Assembly Intake (9) Camshaft Drive Gear
(4) Camshaft Assembly Exhaust (10) Oil Seal
(5) Pulley Fixing Bolt
Disassembly
1. Remove fixing bolt (5) for camshaft drive gear pulley
using the J–43041 universal holder.
014RW060
2. Remove twenty fixing bolts from inlet and exhaust 2. Use a micrometer to measure the diameter and the
camshaft bearing cap on one side bank, then uneven wear of the camshaft journals.
camshaft bearing cap (2). Replace the camshaft if the diameter or the uneven
wear exceeds the specified limit.
Journal Diameter
(1.0225 in–1.0233 in)
Limit : 25.8 mm (1.0157 in)
Uneven wear : 0.05 mm (0.0020 in)
014RW027
3. Remove camshaft assembly (3), (4).

4. Remove three fixing bolts (7) from camshaft drive
gear retainer (8), then camshaft drive gear assembly.

1. Use a micrometer to measure the cam lobe height 014RS023
and uneven wear. Replace the camshaft if either the 3. Place the camshaft on V–blocks.
lobe height or the uneven wear exceeds the specified Slowly rotate the camshaft and measure the runout
limit. with a dial indicator.
Lobe height : 44.709 mm (1.7602 in) Replace the camshaft if the runout exceeds the
Uneven wear : 0.05 mm (0.0020 in) specified limit.
Runout
Limit : 0.1 mm (0.0039 in)
014RW043
014RW044
4. Measure the camshaft journal oil clearance. 5. Replace the cylinder head and/or camshaft if the
1. Measure the camshaft bearing cap housing measured oil clearance exceeds the specified limit.
inside diameter. 1. Carefully clean the camshaft journal, the
camshaft bracket, and the cylinder head.
NOTE: Tighten camshaft bearing cap (2) to specified
torque before measuring the camshaft bearing cap inside 2. Install camshaft assembly and camshaft bearing
diameter. cap (2), tighten twenty bolts (1) on one side bank
014RW031
2. Subtract the camshaft outside diameter from the 014RW031
camshaft bearing cap housing inside diameter. 3. Measure the camshaft thrust clearance with a dial
indicator. Replace the camshaft and/or the
Oil Clearance cylinder head if the camshaft thrust clearance
Standard : 0.027 mm–0.078 mm exceeds the specified limit.
(0.0011 in–0.0031 in)
Camshaft thrust Clearance
Limit : 0.11 mm (0.0043 in) Standard : 0.03 mm–0.08 mm
(0.0012 in.–0.0031 in.)
Limit : 0.12 mm (0.0047 mm)
014RW037
014RW035
Reassembly
three bolts to specified torque.
1. Use J–42686 to turn sub gear to right direction
until the M5 bolt hole aligns between camshaft
driven gear and sub gear.
2. Tighten M5 bolt suitable torque for prevent
moving the sub gear.
014RW020
Legend
(4) Discerning Mark
LI: Left Bank Intake
RI: Right Bank Intake
LE: Left Bank Exhaust
RE: Right Bank Exhaust
014RW041
3. Install camshaft assembly and camshaft bearing

caps, tighten twenty bolts on one side bank to the
specified torque.
1. Apply engine oil to camshaft journal and bearing
dot).
014RW023
Legend
(1) Right Bank Camshaft Drive Gear
(3) Timing Mark on Drive Gear
(4) Dowel Pin
014RW024

3. Tighten twenty bolts in numerical order on one 4. If the oil seal requires replacement, use the J–42985
side bank as shown in the illustration. to install the oil seal.
014RW034
014RW031
5. Tighten bolt for camshaft drive gear pulley to the
specified torque using the J–43041 universal holder.
014RW060
Crankshaft
Crankshaft and Associated Parts
013RW009
Legend (8) Piston and Connecting Rod Assembly

(1) Cylinder Head Assembly (9) Flywheel
(2) Crankcase with Oil Pan (10) Rear Oil Seal Retainer and Oil Seal
(3) Oil Pipe and O-Ring (11) Main Bearing Cap
(4) Oil Strainer and O-Ring (12) Crankshaft
(5) Oil Pump Assembly (13) Main Bearing Cap Fixing Bolts
(6) Cylinder Block Side Bolts (14) Oil Gallery Fixing Bolts
(7) Oil Gallery
Disassembly 2. Remove the main bearing cap fixing bolts in the

sequence shown in the illustration.
1. Remove cylinder head assembly (1). Refer to Arrange the removed main bearing caps in the
“Cylinder Head” in this manual. cylinder number order.
2. Remove crankcase with oil pan (2). Refer to “Oil Pan Remove the main bearings.
and Crankcase” in this manual.
CAUTION: Take care not to damage or deform the
sealing flange surface of crankcase.
3. Remove oil pipe and O-ring (3).
4. Remove oil strainer and O-ring (4).
5. Remove oil pump assembly (5).
6. Remove crankcase side bolts (6).
7. Remove oil gallery (7).
8. Remove piston and connecting rod assembly (8).
Refer to “Piston, Piston Ring and Connecting Rod” in
this manual.
9. Remove flywheel (9).
10. Remove rear oil seal retainer (10).
11. Remove main bearing cap (11).
12. Remove crankshaft (12).
Inspection and Repair 015RS004
1. Crankshaft 3. Remove the crankshaft.

Set the dial indicator as shown in the illustration and Remove the main bearings.
measure the crankshaft thrust clearance. If the thrust 4. Clean the upper and lower bearings as well as the
clearance exceeds the specified limit, replace the crankshaft main journal.
thrust bearings as a set.
5. Check the bearings for damage or excessive wear.
Thrust Clearance The bearings must be replaced as a set if damage or
Standard : 0.06 mm–0.24 mm excessive wear is discovered during inspection.
(0.0024 in–0.0094 in) 6. Set the upper bearings and the thrust washers to their
Limit : 0.30 mm (0.0118 in) original positions.
Carefully install the crankshaft.
7. Set the lower bearings to the bearing cap original
position.
8. Apply plastigage to the crankshaft journal unit as
shown in the illustration.
NOTE: Do not set the plastigage on the oil hole.
015RS003
Main Bearing Clearance

1. Remove the bearing caps and measure the oil
clearance.
015RS005
9. Install main bearing caps, oil gallery and crank case Standard : 0.019 mm–0.043 mm
bolts in the order shown, and tighten each bolt to the (0.0007 in–0.0017 in)
specified torque.
Limit : 0.08 mm (0.0031 in)
NOTE: Do not apply engine oil to the crank case side
bolts.
Main bearing cap bolts.
Oil gallery fixing bolts.
Torque:
1st step: 29 N·m (21 lb ft)
2nd step 55°∼ 65°
Crank case side bolts
Torque : 39 N·m (29lb ft)
NOTE: Do not allow the crankshaft to rotate.
015RS008
12. Clean the plastigage from the bearings and the

crankshaft.
Remove the crankshaft and the bearings.
Crankshaft (12) Inspection

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

015RS006
1. Carefully set the crankshaft on the V–blocks. Slowly
10. Remove the main bearing caps in the sequence rotate the crankshaft and measure the runout. If the
shown in the illustration. crankshaft runout exceeds the specified limit, the
crankshaft must be replaced.
Runout : 0.04 mm (0.0016 in)
015RS004
11. Measure the plastigage width and determine the oil

clearance. If the oil clearance exceeds the specified 015RS007
limit, replace the main bearings as a set and/or

replace the crankshaft.
2. Measure the diameter and the uneven wear of main 2. Diameter size mark (1).
journal and crank pin. If the crankshaft wear exceeds The diameter size marks are stamped on the No.1
the specified limit, crankshaft must be replaced. crankshaft balancer as shown in the illustration.
Main journal diameter : 63.918 mm–63.933 mm
(2.5165 in–2.5170 in)
Crank pin diameter : 53.922 mm–53.937 mm
(2.1229 in.–2.1235 in.)
Uneven wear limit : 0.005 mm (0.0002 in)
015RS011
NOTE: Take care to ensure the bearings are positioned

correctly.
015RS009
Crankshaft Bearing Selection

When installing new crankshaft bearings or replacing
bearings, refer to the selection table below. Select and
install the new crankshaft bearings, paying close
attention to the cylinder block journal hole.
1. Diameter size mark (1) and the crankshaft journal.
015RS012
Legend
(1) Number 1 and 4 main bearing upper and lower
(2) Number 2 and 3 main bearing upper
(3) Number 2 and 3 main bearing lower
015RS010
Crank Crank
Shaft Shaft
1 Size Main Bearing Crank Shaft Main 2 Size Bearing Bearing Oil Clearance
Mark Bore Diameter Journal Diameter Mark Size Mark Size Mark (Reference)
(Upper (Lower
Side) Side)
63.918-63.925 0.030-0.049
2 Blue Blue
68.994-69.000 (2.5165-2.5167) (0.0012-0.0019)
1
(2.7163-2.7165) 63.926-63.933 0.028-0.047
1
(2.5168-2.5170) (0.0011-0.0019)
Brown Brown
63.918-63.925 0.029-0.048
2
68.987-68.993 (2.5165-2.5167) (0.0011-0.0019)
2
(2.7160-2.7163) 63.926-63.933 0.027-0.046
1
(2.5168-2.5170) (0.0011-0.0018)
Green Green
63.918-63.925 0.028-0.047
2
68.980-68.986 (2.5165-2.5167) (0.0011-0.0019)
3
(2.7157-2.7160) 63.926-63.933 0.026-0.045
1 Yellow Yellow
(2.5168-2.5170) (0.0010-0.0018)
Reassembly D Carefully mount the crankshaft.
1. Crankshaft (12) D Apply engine oil to the thrust washer.

D Install the main bearings to the cylinder block and D Assemble the thrust washer to the No.3 bearing
the main bearing caps. journal. The oil grooves must face the crankshaft.
D Be sure that they are positioned correctly.
D Apply new engine oil to the upper and lower main
bearing faces.
NOTE: Do not apply engine oil to the main bearing back
faces.
015RS013
2. Rear oil seal (10)

D Remove the oil from the cylinder block and the
retainer mounting surface.
D Apply sealant (TB–1207B or equivalent) to the
retainer mounting surface, following the pattern
015RS012 shown in the illustration.
The retainer must be installed within 5 minutes after
sealant application befor the sealant hardens.
015RW002 015RS017
Legend 3. Flywheel (9)

(1) Around Bolt Holes 1. Thoroughly clean and remove the oil from the
(2) Around Dowel Pin threads of crankshaft.
2. Remove the oil from the crankshaft and flywheel
D Apply engine oil to the oil seal lip. mounting faces.
D Align the cylinder block dowel pin holes with the rear 3. Mount the flywheel on the crankshaft and then
retainer dowel pins. install the washer.
D Tighten the rear retainer fixing bolts. New bolts 4. Hold the crankshaft to prevent from rotating then
should be used when installing rear retainer. install the bolts in the order shown to the specified
torque.
NOTE: Be very careful not to disengage the oil seal garter
spring during installation of the rear retainer. NOTE: Do not reuse the bolt and do not apply oil or thread
lock to the bolt.
If the seal was removed from retainer for
replacement, apply engine oil to the oil seal lip and
install the oil seal using J–39201 oil seal installer.
015RS018
015RW001
4. Piston and connecting rod assembly (8)
D Apply engine oil to the cylinder bores, the
connecting rod bearings and the crankshaft pins.
Check to see that the piston ring end gaps are
correctly positioned.
015RS020
5. Install oil gallery (7) and tighten the bolts in 2 steps, in

the order shown.
1st step: 29 N·m (22 lb ft)
2nd step: 55°∼ 65°
015RS019
Legend
(1) No.1 Compression Ring
(2) No.2 Compression Ring
(3) Oil Ring Side Rail Upper
(4) Oil Ring Side Rail Lower
(5) Piston Front Mark
D Insert the piston/connecting rod assemblies into

each cylinder with the piston ring compressor. The
front marks must be facing the front of the engine.
D Match the numbered caps with the numbers on the
connecting rods. Align the punched marks on the
connecting rods and caps.
D Apply engine oil to the threads and seating faces of
the nuts.
D Tighten the nuts.
051RS009
6. Cylinder block side bolts (6)
After tightening the cap nuts, check to see that the
D Tighten all the bolts to the specified torque in the
order shown.
NOTE: Do not apply engine oil to the bearing back faces. NOTE: Do not apply engine oil to the crank case side
bolts.
012RS001 013RW010
7. Install oil pump assembly (5), refer to “Oil pump” in Legend

this manual. (1) Portion Between Bolt Holes
8. Install oil strainer and O-ring (4). (2) Bolt Hole Portion
9. Install oil pipe and O-ring (3) and tighten the bolts.
Torque: 25 N·m (18 lb ft) 11. Install cylinder head assembly, refer to “Cylinder
head” in this manual.
10. Install crankcase with oil pan (2).
1. Completely remove all residual sealant, lubricant
and moisture from the sealing surfaces. The
surfaces must be perfectly dry.
2. Apply a correct width bead of sealant (TB—
1207C or its equivalent) to the contact surfaces of
the oil pan. There must be no gaps in the bead.
3. The crankcase assembly must be installed within
5 minutes after sealant application to prevent
premature hardening of the sealant.
4. Tighten the bolts and nuts to the specified torque.
Piston and Connecting Rod

Piston, Connecting Rod and Associate Parts
015RW019
Legend (7) Piston and Connecting Rod Assembly

(1) Cylinder Head Assembly (8) Piston Ring
(2) Cylinder Head Gasket (9) Piston Pin
(3) Crankcase with Oil Pan (10) Piston
(4) Oil Pipe and O-Ring (11) Connecting Rod
(5) Oil Strainer and O-Ring (12) Connecting Rod Cap
(6) Oil Gallery
Disassembly 5. Remove oil strainer and O-ring (5).

6. Remove oil gallery (6).
1. Remove cylinder head assembly (1). Refer to
“Cylinder Head Removal” in this manual. 7. Remove connecting rod cap with connecting rod
lower bearing (12).
2. Remove cylinder head gasket (2).
8. Remove piston and connecting rod assembly (7).
3. Remove crankcase with oil pan (3). Refer to“Oil Pan
and Crankcase” in this manual. NOTE: Before removing piston and connecting rod
4. Remove oil pipe and O-ring (4). assembly, measure thrust clearance.
015RS031 015RS023
D Remove any ridge or carbon build up from the top Legend

end of the cylinder.
(1) Press Ram
9. Remove the piston rings (8) with a piston ring (2) Piston
expander. Arrange the removed piston rings in the
(3) Connecting Rod
cylinder number order.
(4) Piston Pin
11. Piston (10)

12. Connecting rod (11)

Pistons (10)
Carefully clean away all the carbon adhering to the piston
head and the piston ring grooves.
NOTE: Never use a wire brush to clean the pistons.
Damage will result. Visually check each piston for
cracking, scoring, and other signs of excessive wear. If
any of the above conditions are found, the piston must be
replaced.
Piston Diameter
1. Measure the piston outside diameter with micrometer
015RS022 at the piston grading position and a right angle to the
10. Remove the piston pin (9) using J–24086–C piston piston pin.
pin service set and piston support with a press. Piston grading position (from piston head)
NOTE: Keep the parts removed from each cylinder Piston grading position : 43.0 mm (1.6929 in)
separate. All parts must be reinstalled in their original
positions. Heating the connecting rod will permit easy
removal of the piston pin.
015RV014 012RS002
The size mark (1) for piston outside diameter is

represented as shown in illustration below. Piston Rings (8)
Outside Diameter Any worn or damaged part discovered during engine
overhaul must be replaced with a new one.
Size Mark A : 93.360 mm–93.370 mm
(3.6756 in–3.6760 in) 1. Ring end gap measurement
D Insert the piston ring into the bore.
Size Mark B : 93.371 mm–93.380 mm
(3.6760 in–3.6764 in) D Push the ring by the piston, at a right angle to the
wall, into the point at which the cylinder bore
Size Mark C : 93.381 mm–93.390 mm diameter is the smallest.
(3.6764 in–3.6768 in)
D Measure the ring end gap.
Compression Ring
1st ring
Standard: 0.300 mm–0.400 mm
(0.0118 in–0.0157 in)
Limit: 1.0 mm (0.0394 in)
2nd ring
(0.0177 in–0.0236 in)
Limit: 1.2 mm (0.0472 in)
Oil ring
(0.0059 in–0.0177 in)
Limit: 1.05 mm (0.0413 in)
015RS025
Measure the cylinder bore inside diameter (refer to

“Cylinder Block” in this manual).
015RS026 015RS028
D Positioning mark (1) is painted as shown in the

illustration. Piston Pin (9)
Marked T : No.1 Compression ring NOTE: Do not reuse the old piston pin.
Marked T2 : No.2 Compression ring 1. Use a micrometer to measure the new piston pin
outside diameter in both directions at three different
positions.
2. Measure the inside diameter of the connecting rod
small end. If the fitting interference between the small
end and pin does not conform to the specified value,
the connecting rod must be replaced.
Standard : 0.023 mm–0.038 mm (0.0009
in–0.0015 in)
015RS027
2. Measure the clearance between the piston ring

groove and the piston ring with a feeler gauge. If the
piston ring groove / piston ring clearance exceeds the
specified limit, the piston must be replaced.
Compression Ring Clearance
(0.0006 in.–0.0015 in)
015RS029
Limit : 0.15mm (0.0059 in)
3. Insert the new pin into the piston and rotate it. If the
pin rotates smoothly with no backlash, the clearance
is normal. If there is backlash or roughness, measure
the clearance. If the clearance exceeds the specified
limit, the piston must be replaced.
Clearance
(0.0004 in.–0.0007 in)
Limit : 0.040 mm (0.0016 in)
Connecting Rods (11)

1. Check the connecting rod alignment If either the bend
or the twist exceeds the specified limit, the connecting
rod must be replaced.
Bend per 100 mm (3.937 in)
Limit: 0.15 (0.0059)
Twist per 100 mm (3.937 in)
Limit: 0.20 (0.0078) 015RS031
3. Measure the oil clearance between the connecting

rod and the crankshaft.
1. Remove the connecting rod cap nuts and the rod
caps (12).
Arrange the removed rod caps in the cylinder
number order.
2. Clean the rod bearings and the crankshaft pins.
3. Carefully check the rod bearings. If even one
bearing is found to be damaged or badly worn, the
entire bearing assembly must be replaced as a
set. Reinstall the bearings in their original
positions. Apply plastigage to the crank pin.
015RS030
2. Measure the connecting rod thrust clearance. Use a

feeler gauge to measure the thrust clearance at the
large end of the connecting rod If the clearance
exceeds the specified limit, the connecting rod must
be replaced.
(0.0063 in.–0.0138 in)
Limit : 0.40 mm (0.0157 in)
015RS032
4. Reinstall the rod caps (12) to their original

positions.
Tighten the rod cap nuts.
NOTE: Do not allow the crankshaft to rotate.
5. Remove the rod caps. 7. Clean the plastigage from the bearings and the
crankshaft pins.
6. Measure the width of the plastigage and
determine the oil clearance. If the oil clearance
exceeds the limit, replace the rod bearing as a Con–rod Bearing Selection
set. Select and install the new connecting rod bearings,
Standard : 0.019 mm–0.043 mm paying close attention to the connecting rod big end
diameter size mark (1).
(0.0007 in–0.0017 in)
Limit : 0.08 mm (0.003 in) NOTE: Take care not to confuse the alignment mark (2)
and the size mark (1) during the installation procedure.
015RS008
015RS034
Connecting Rod Color of

Big end Bore Crankshaft Pin Oil Clearance
1 Size Mark Bearing Thickness Size
Diameter Diameter (Reference)
(Reference) Mark
56.994-57.000 1.512-1.516 0.025-0.054
A Yellow
(2.2439-2.2441) (0.0595-0.0597) (0.0010-0.0021)
56.988-56.994 53.922-53.937 1.508-1.512 0.027-0.056
B Green
(2.2436-2.2439) (2.1229-2.1235) (0.0594-0.0595) (0.0011-0.0022)
56.982-56.988 1.504-1.508 0.029-0.058
C Pink
(2.2434-2.2436) (0.0592-0.0594) (0.0011-0.0023)
Reassembly
1. Install connecting rod
2. Install piston
3. Install piston pin
D Apply a thin coat of engine oil to the piston pin. Try to
insert the piston pin into the piston pin hole with
normal finger pressure.
NOTE: When changing piston / connecting rod
combinations, do not change the piston / piston pin
combination and do not reuse the old piston pin.
D Attach the piston to the connecting rod with the
piston front mark and the connecting rod front mark
on the same side.
015RS036
D With J–24086–C Piston pin service set and a press, D Install piston rings in the following sequence.
press fit the piston pin. 1. Oil ring
NOTE: Heat the connecting rod small end to a suitable 1. Expander ring
temperature to ensure smooth installation. 2. Upper side rail
3. Lower side rail
2. 2nd compression ring
3. 1st compression ring
D The compression rings must be set with the T or T2
mark facing up.
Marked T : No.1 Compression ring
Marked T2 : No.2 Compression ring
D After installation, apply engine oil to the entire
circumference of the piston rings. Check to see that
all the rings rotate smoothly.
015RS037
Legend
(1) Press Ram
(2) Piston
(3) Connecting Rod
(4) Piston Pin
4. Install piston ring with the piston ring expander.

The compression ring must be set with the T mark (1)
facing up.
Marked T : No.1 Compression ring
Marked T2 : No.2 Compression ring 015RS038
5. Install piston and connecting rod assembly.

D Insert the bearings into the connecting rods and
caps. Apply new engine oil to the bearing faces and
nuts.
D Tighten the connecting rod cap nuts
NOTE: Do not apply engine oil to the bearing back faces.
6. Oil gallery, refer to “Crankshaft and main bearing” in
this manual.
7. Oil strainer and O-ring.
8. Oil pipe and O-ring.
9. Install crankcase with oil pan, refer to “Oil pan and
Crankcase” in this manual.
10. Install cylinder head gasket.
11. Install Cylinder head assembly.
D Refer to “Cylinder head” in this manual.
015RS027
Cylinder Block
Cylinder Block and Associated Parts
012RW010
Legend (8) Oil Gallery

(1) Cylinder Head Assembly (9) Piston and Connecting Rod Assembly
(2) Cylinder Head Gasket (10) Flywheel
(3) Crankcase with Oil Pan (11) Rear Oil Seal Retainer Assembly
(4) Oil Pipe and O-Ring (12) Main Bearing Cap
(5) Oil Strainer and O-Ring (13) Crankshaft
(6) Oil Pump Assembly (14) Cylinder Block
(7) Cylinder Block Side Bolts
Disassembly 5. Remove oil strainer and O-ring.

6. Remove oil pump assembly.
7. Remove crankcase side bolts.
2. Remove cylinder head gasket.
8. Remove oil gallery.
3. Remove crankcase with oil pan.
9. Remove piston and connecting rod assembly.
4. Remove oil pipe and O-ring.
10. Remove flywheel.
11. Remove rear oil seal retainer assembly. Cylinder Bore
12. Remove main bearing cap. Use a cylinder gauge to measure the cylinder bore
13. Remove crankshaft. diameter in both the axial and thrust directions. Each
14. Remove cylinder block. measurement should be made at six points.
CAUTION: Be very careful not to allow any material
to accidentally drop into the upper surface of the
Inspection and Repair cylinder block. Be very careful not to scratch the
1. Remove the cylinder head gasket and any other upper surface of the cylinder block.
material adhering to the upper surface of the cylinder Cylinder Bore Inside Diameter
block. Be very careful not to allow any material to
Limit : 93.530 (3.6823)
accidentally drop into the cylinder block. Be very
careful not to scratch the cylinder block. If the measurement exceed the specified limit, the
cylinder block must be replaced.
2. Carefully remove the oil pump, rear oil seal retainer,
and crankcase assembly installation surface seal. Diameter
3. Wipe the cylinder block clean. Grade A : 93.400 mm–93.410 mm
4. Visually inspect the cylinder block. If necessary, use a (3.6772 in–3.6776 in)
flaw detector to perform a dye penetrate and Grade B : 93.411 mm–93.420 mm
hydraulic (or air pressure) test. If cracking or other (3.6776 in–3.6779 in)
damage is discovered, the cylinder block must either
Grade C : 93.421 mm–93.430 mm
be repaired or replaced.
(3.6780 in–3.6783 in)
Flatness
1. Using a straight–edge and feeler gauge, check that
the upper surface of the cylinder block is not warped.
CAUTION: Be very careful not to allow any material
to accidentally drop into the upper surface of the
cylinder block. Be very careful not to scratch the
upper surface of the cylinder block.
2. The cylinder block must be reground or replaced if the
warpage exceeds the limit.
Warpage
Limit : 0.15 mm (0.0059 in)
Maximum repairable limit: 0.15 mm (0.0059 in)
012RS005
NOTE: For information on piston diameter, please refer

to the section ”Inspection of the Piston and Connecting
Rod Assembly” in this manual.
012RS004
D The ”Grade” mark (1) is stamped at the position D Carefully mount the crankshaft.
illustrated.
D Apply engine oil to the thrust washer.
D Assemble the thrust washer to the No. 3 bearing
journal. The oil grooves must face the crankshaft.
012RS006
Reassembly
015RS013
1. Install cylinder block. 3. Install rear oil seal retainer.

2. Install crankshaft. D Remove oil on cylinder block and retainer fitting
D Install the main bearings to the cylinder block and surface.
the main bearing caps. D Apply sealant (TB1207B or equivalent) to retainer
D Be sure that they are positioned correctly. fitting surface as shown in illustration.
D Apply new engine oil to the upper and lower main D The oil seal retainer must be installed within 5
bearing faces. minutes after sealant application before the sealant
hardens.
NOTE: Do not apply engine oil to the bearing back faces.
015RW002
015RS012
Legend
Legend (1) Around Bolt Holes
(1) Number 1 and 4 main bearing upper and lower. (2) Around Dowel Pin
(2) Number 2 and 3 main bearing upper.
(3) Number 2 and 3 main bearing lower.
D Apply engine oil to oil seal lip and align a dowel pin 5. Install piston and connecting rod assembly.
hole in the cylinder block with that in the retainer. D Apply engine oil to the cylinder bores, the
D Tighten retainer fixing bolts to the specified torque. connecting rod bearings and the crankshaft pins.
Torque: 25 N·m (18.4 lb ft) NOTE: Do not apply engine oil to the bearing back faces.
D Check to see that the piston ring end gaps are
correctly positioned.
015RW001
4. Install flywheel
1. Thoroughly clean and remove the oil from the 015RS019
threads of crankshaft. Legend

2. Remove the oil from the crankshaft and flywheel (1) No.1 Compression Ring
mounting faces. (2) No.2 Compression Ring
3. Mount the flywheel on the crankshaft and then (3) Oil Ring Side Rail Upper
install the washer. (4) Oil Ring Side Rail Lower
4. Holding the crankshaft stationary, tighten the (5) Piston Front Mark
flywheel bolts in the order shown.
D Insert the piston/connecting rod assemblies into
Torque: 54 N·m (40 lb ft) each cylinder with the piston ring compressor.
NOTE: Do not reuse the bolts and do not apply oil or D The front marks (1) must be facing the front of the
thread lock to the bolts. engine.
015RS018
015RS020
6. Install oil gallery and tighten the bolts in 2 steps in the 8. Install oil pump assembly. Refer to “Oil Pump” in this
order shown. manual.
1st step : 29 N·m (22 lb ft) 9. Install oil strainer and O-ring.
2nd step : 55°∼ 65° 10. Install oil pipe and O-ring.
11. Install crankcase with oil pan.
1. Completely remove all residual sealant, lubricant
and moisture from the sealing surfaces. The
surfaces must be perfectly dry.
2. Apply a correct width bead of sealant (TB– 1207C
or its equivalent) to the contact surfaces of the
crankcase. There must be no gaps in the bead.
3. The oil pan must be installed within 5 minutes
after sealant application to prevent premature
hardening of sealant.
4. Tighten the bolts and nuts to the specified torque.
012RS007
7. Install cylinder block side bolts (1) and tighten

crankcase bolts in sequence shown in the illustration.
013RW010
Legend
(1) Portion Between Both Holes
(2) Bolt Hole Portions
12. Install cylinder head gasket.

13. Install cylinder head assembly. Refer to “Cylinder
Head” in this manual.
012RW005
Main Data and Specification

Specifications
Item
6VE1
Engine type, number of cylinders and arrangement Water cooled, four cycle V6
Form of combustion chamber Pent roof type
Valve mechanism 4-Cams, 4-Valves, DOHC Gear & Belt Drive
Cylinder liner type Casted in cylinder drive
Total piston displacement 3494 cc
Cylinder bore x stroke 93.4mm x 85.0mm
(3.677 in x 3.346 in)
Compression ratio 9.1 : 1
Compression pressure at 300rpm 14.0 Kg/cm@
Engine idling speed rpm Non adjustable (750)
Valve clearance Intake: 0.28 mm (0.11 in)
Exhaust: 0.30mm (0.12in)
Oil capacity 5.3 liters
Ignition timing Non adjustable (20° BTDC at idle rpm)
Spark plug K16PR–P11, PK16PR11, RC10PYP4
Plug gap 1.0 mm–1.1 mm(0.0394 in – 0.0433 in)
Ignition coil, Spark plug, Crankshaft position sensor and Under cover
E06RY001
Cylinder head cover, Cylinder head, Camshaft bearing cap, Common chamber, EGR valve and EGR pipe, Ion
sensing module
E06RY00001
Crankshaft main bearing, Flywheel, Crankcase, Oil pan, Timing belt tensioner, Timing pulley, Timing belt
cover, Oil pump, Oil gallery, Oil strainer and Water pump
E06RW002
Connecting rod and Water pump
E06RW011
Engine mount
E06RW003
Special Tool
TOOL NO. TOOL NO.
TOOL NAME TOOL NAME
J–42985
J–21687–02
Installer; Camshaft oil
Remover; tie rod end
seal
J–36390 J–39206
Wrench; Oil filter Installer; Pilot bearing
J–8062
Compressor; Valve
spring (1) J–8614–01
J–42898 Holder; Crankshaft
Adapter; Compressor,
Valve spring (2)
J–37281 J–37228
Remover; Oil controller Seal cutter
J–38537 J–39201
Installer; Oil controller Installer; Real oil seal
J–29107 J–39202
Universal pitman arm Installer; Oil pump oil
puller seal
TOOL NO.
ILLUSTRATION
TOOL NAME
J–24239–1
Cylinder head bolt
wrench
J–42899
Replacer; Valve guide
(1, 2)
J–42687
Installer; Valve guide (1)
J–37985–1
Remover; Valve guide
(2)
J–42689
Adjusting Tool: Valve
clearance
J–42686
Lever; Gear spring
J–43041
Holder; Universal
ENGINE COOLING 6B–1
TROOPER
ENGINE
ENGINE COOLING
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 6B–1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–8
General Description . . . . . . . . . . . . . . . . . . . . . 6B–2 Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–9
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–5 Radiator and Associated Parts . . . . . . . . . . 6B–9
Draining and Refilling Cooling System . . . . . 6B–6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–9
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–7 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–10
Water Pump and Associated Parts . . . . . . . 6B–7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–7 Drive Belt and Cooling Fan . . . . . . . . . . . . . . . 6B–12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–7 Drive Belt and Associated Parts . . . . . . . . . 6B–12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–7 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–12
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–12
Thermostat and Associated Parts . . . . . . . . 6B–8 Main Data and Specifications . . . . . . . . . . . . . 6B–13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–8 Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B–8

systems.
6B–2 ENGINE COOLING
General Description
030RW001
Legend (7) Cylinder Head

(1) Water Pump (8) Right Bank
(2) Thermostat (9) Throttle Body
(3) Radiator (10) Cylinder Block
(4) Reserve Tank (11) Cylinder Head
(5) Cooling Fan (12) Left Bank
(6) Cylinder Block (13) Heater
The cooling system is a pressurized Engine Coolant (EC)

forced circulation type which consists of a water pump,
thermostat cooling fan, radiator and other components.
The automatic transmission fluid is cooled by the EC in
radiator.
Water Pump
The EC pump is a centrifugal impeller type and is driven
by a timing belt.
030RS001
Thermostat Anti Freeze Solution

The thermostat is a wax pellet type with a air hole(1) and is D Relation between the mixing ratio and freezing
installed in the thermostat housing. temperature of the EC varies with the ratio of
anti–freeze solution in water. Proper mixing ratio can
be determined by referring to the chart. Supplemental
inhibitors or additives claiming to increase cooling
capability that have not been specifically approved by
Isuzu are not recommended for addition to the cooling
system.
D Calculating mixing ratio
031RW002
Radiator
The radiator is a tube type with corrugated fins. In order to
raise the boiling point of the coolant, the radiator is fitted
with a cap in which the valve is operated at 88.2 ∼ 117.6
kPa (12.8 ∼ 17.0 psi) pressure. (No oil cooler provided for
M/T) F06RW005
NOTE: Antifreeze solution + Water = Total cooling

system capacity.
D Total Cooling System Capacity
D M/T 8.8Lit (2.32Us gal)
D A/T 8.4Lit (2.22Us gal)
110RS001
B06RW002 B06RW003
D Mixing ratio
Check the specific gravity of engine coolant in the
cooling system temperature ranges from 0°C to 50°C
using a suction type hydrometer, then determine the
density of the engine coolant by referring to the table.
NOTE:
1. Even in the areas where the atmospheric
temperature is higher than 0°C, be sure not to use
antifreeze solution at a mixing ratio lower than 20% so
that the inside of the engine may not be corroded.
2. If antifreeze solution is used at a mixing ratio higher
than 60%, the specific heat of the coolant falls and the
engine may be overheated. Moreover, antifreeze
performance drop and the coolant may be frozen.
The density of the solution must be adjusted as
occasion calls.
Antifreeze solution lower than 20% may not have
sufficient anticorrosive performance, and therefore,
please never fail to adjust as occasion demands within
the range of 20% to 60%.
Diagnosis
Engine Cooling Trouble
Engine overheating Low Engine Coolant level Replenish
Incorrect fan installed Replace
Thermo meter unit faulty Replace
Faulty thermostat Replace
Faulty Engine Coolant temperature Repair or replace
sensor
Clogged radiator Clean or replace
Faulty radiator cap Replace
Low engine oil level or use of Replenish or change oil
improper engine oil
Clogged exhaust system Clean exhaust system or replace
faulty parts
Faulty Throttle Position sensor Replace throttle valve assembly
Open or shorted Throttle Position Repair or replace
sensor circuit
Damaged cylinder head gasket Replace
Engine overcooling Faulty thermostat Replace
Engine slow to warm–up Faulty thermostat Replace
Thermo unit faulty Replace
Draining and Refilling Cooling 9. After the engine has cooled, replenish with EC up to
the “MAX” line of the reserve tank.
System 10. Start the engine. With the engine running at 3,000
Before draining the cooling system, inspect the system rpm, make sure there is no running water sound from
and perform any necessary service to ensure that it is the heater core (behind the center console).
clean, does not leak and is in proper working order. The
11. If the running water sound is heard, repeat steps 8 to
engine coolant (EC) level should be between the “MIN”
10.
and “MAX” lines of reserve tank when the engine is cold.
If low, check for leakage and add EC up to the “MAX” line.
There should not be any excessive deposit of rust or
scales around the radiator cap or radiator filler hole, and
the EC should also be free from oil.
Replace the EC if excessively dirty.
1. Completely drain the cooling system by opening the
drain plug (2) at the bottom of the radiator.
110RW002
2. Remove the radiator cap.

WARNING: TO AVOID THE DANGER OF BEING
BURNED, DO NOT REMOVE THE CAP WHILE THE
ENGINE AND RADIATOR ARE STILL HOT.
SCALDING FLUID AND STEAM CAN BE BLOWN OUT
UNDER PRESSURE.
3. Disconnect all hoses from the EC reserve tank.
Scrub and clean the inside of the reserve tank with
soap and water. Flush it well with clean water, then
drain it. Install the reserve tank and hoses.
4. Refill the cooling system with the EC using a solution
that is at least 50 percent antifreeze but no more than
70 percent antifreeze.
5. Fill the radiator to the base of the filler neck.
Fill the EC reserve tank to “MAX” line when the engine
is cold.
6. Block the drive wheels and firmly apply the parking
brake. Shift an automatic transmission to “P” (Park)
or a manual transmission to neutral.
7. Remove the radiator cap. Start the engine and warm
it up at 2,500 ∼ 3,000 rpm for about 30 minutes.
8. When the air comes out from the radiator filler neck
and the EC level has gone down, replenish with the
EC. Repeat this procedure until the EC level does not
go down. Then stop the engine and install the radiator
cap. Let the engine cool down.
Water Pump
Water Pump and Associated Parts
030RS002
Legend (3) Water Pump Assembly

(1) Timing Belt (4) Gasket
(2) Idle Pulley
Removal 2. Install water pump assembly and tighten bolts to the

specified torque.
2. Drain coolant.
D Tightening order
3. Radiator hose (on inlet pipe side).
The tightening order are in the illustrate.
4. Remove timing belt. Refer to “Timing Belt” in this
manual. NOTE: To prevent the oil leakage, apply the LOCTITE
5. Remove Idle pulley. 262 or an equivalent, to the arrow marked fixing bolt
thread.
6. Remove water pump assembly.
7. Remove gasket.
Inspection
Make necessary repair and parts replacement if extreme
wear or damage is found during inspection. Should any of
the following problems occur, the entire water pump
assembly must be replaced:
D Crack in the water pump body
D EC leakage from the seal unit
D Play or abnormal noise in the bearing
D Cracks or corrosion in the impeller.
Installation
1. Install gasket, clean the mating surface of gasket
before installation.
030RW008
3. Idle pulley 4. Timing belt
D Install idle pulley and tighten bolt to the specified D Install timing belt. Refer to timing belt installation
torque. step in “Timing Belt” in this manual.
Torque: 52 N·m (38 lb ft) 5. Connect radiator inlet hose and replenish EC.
6. Connect battery ground cable.
Thermostat
Thermostat and Associated Parts
031RS003
Confirm the temperature when the valve first begins to

031RW001 open.
Legend Valve opening temperature 74.5C ∼ 78.5°C
(1) Thermostat Housing (166.1°F ∼ 173.3°F)
(2) Thermostat Confirm the temperature when the valve is fully opened.
(3) Outlet Pipe Valve full open temperature and lift More than
8.5mm (0.33 in) at 90°C (194°F)
Make necessary repair and parts replacement if extreme
Removal wear or damage is found during inspection.

2. Drain engine coolant from the radiator and engine.
Installation
3. Disconnect radiator hose from the inlet pipe. 1. Install thermostat into the outlet pipe(4) making sure
that the air hole is in the up position.
4. Remove thermostat housing.
2. Install thermostat housing and tighten bolts to the
5. Remove thermostat(2).
specified torque.
Inspection 3. Installation rubber hose.
Suspend the thermostat in a water–filled container using
4. Replenish engine coolant (EC).
thin wire. Place a thermometer next to the thermostat.
Do not directly heat the thermostat. 5. Start engine and check for EC leakage.
Gradually increase the water temperature. Stir the water
so that the entire water is same temperature.
Radiator
Radiator and Associated Parts
110RW003
Legend (4) Reserve Tank Hose

(1) Oil Cooler Hose For Automatic Transmission (5) Bracket
(2) Radiator Hose (6) Radiator Assembly
(3) Fan Guide, Lower (7) Reserve Tank
Removal 5. Remove fan guide(1), clips(3) on both sides and the

bottom lock, then remove lower fan guide(3) with fan
1. Disconnect battery ground cable. shroud(4).
2. Loosen a drain plug(2) to drain EC.
3. Disconnect oil cooler hose(1) on automatic
transmission (A/T).
4. Disconnect radiator inlet hose and outlet hose from
the engine.
110RW001
110RW002
6. Disconnect the reserve tank hose(4) from radiator. Valve opening vacuum kPa (psi) 1.96 ∼ 4.91
7. Remove bracket(5). (0.28 ∼ 0.71)
110RW004 110RS006
8. Lift up and remove the radiator assembly with hose,

taking care not to damage the radiator core with a fan Radiator Core
blade. 1. A bent fin may result in reduced ventilation and
9. Remove rubber cushions on both sides at the bottom. overheating may occur. All bent fins must be
straightened. Pay close attention to the base of the fin
when it is being straightened.
Inspection 2. Remove all dust, bugs and other foreign material.
Radiator Cap
Measure the valve opening pressure of the pressurizing
Flushing the Radiator
valve with a radiator filler cap tester. Thoroughly wash the inside of the radiator and the engine
Replace the cap if the valve opening pressure is outside coolant passages with cold water and mild detergent.
the standard range. Remove all signs of scale and rust.
Valve opening pressure kPa (psi) 88.3 ∼ 117.7 Cooling System Leakage Check
(12.8 ∼17.1)
Use a radiator cap tester to force air into the radiator
Cap tester: J–24460–01
through the filler neck at the specified pressure of 196 kPa
Adapter: J–33984–A
(28.5 psi) with a cap tester:
Check the condition of the vacuum valve in the center of
the valve seat side of the cap. If considerable rust or dirt is D Leakage from the radiator
found, or if the valve seat cannot be moved by hand, clean D Leakage from the coolant pump
or replace the cap. D Leakage from the water hoses
D Check the rubber hoses for swelling.
Cap tester: J–24460–01 8. Connect battery ground cable.
Adapter: J–33984–A 9. Pour engine coolant up to filler neck of radiator, and
up to MAX mark of reserve tank.
110RS005
111RS001
Installation Important operation (in case of 100% engine coolant

change) procedure for filling with engine coolant.
1. Install rubber cushions on both sides of radiator
bottom. Engine Coolant Filling Up Procedure
2. Install radiator assembly with hose, taking care not to 1. Make sure that the engine is cool.
damage the radiator core with a fan blade.
WARNING: WHEN THE COOLANT IS HEATED TO A
3. Install bracket (6) and support the radiator upper tank HIGH TEMPERATURE, BE SURE NOT TO LOOSEN
with the bracket (5) and secure the radiator. OR REMOVE THE RADIATOR CAP. OTHERWISE YOU
4. Connect reserve tank hose (4). MIGHT GET SCALDED BY HOT VAPOR OR BOILING
5. Install lower fan guide (3). WATER. TO OPEN THE RADIATOR CAP, PUT A
6. Connect radiator inlet hose and outlet hose to the PIECE OF THICK CLOTH ON THE CAP AND LOOSEN
engine. THE CAP SLOWLY TO REDUCE THE PRESSURE
WHEN THE COOLANT HAS BECOME COOLER.
7. Connect oil cooler hose (1) to automatic
transmission. 2. Open radiator cap pour coolant up to filler neck.
3. Pour coolant into reservoir tank up to “MAX” line.
4. Tighten radiator cap and start the engine. After idling
for 2 to 3 minutes, stop the engine and reopen radiator
cap. If the water level is lower, replenish.
5. After replenish the coolant tighten radiator cap, warm
up the engine at about 2000 rpm. Set heater
adjustment to the highest temperature position, and
let the coolant circulate also into heater water system.
6. Check to see the thermometer, continuously idling 5
minutes and stop the engine.
7. When the engine has been cooled, check filler neck
for water level and replenish if required. Should
extreme shortage of coolant is found, check the
coolant system and reservoir tank hose for leakage.
8. Pour coolant into the reservoir tank up to “MAX” line.
110RW004
Drive Belt and Cooling Fan

Drive Belt and Associated Parts
015RW005
Legend (4) Water Pump and Cooling Fan Pulley

(1) Crankshaft Pulley (5) Idle Pulley
(2) Generator (6) Tension Pulley
(3) Power Steering Pump (7) Drive Belt
The drive belt adjustment is not required as automatic Installation

drive belt tensioner is equipped.
Install cooling fan assembly and tighten bolts/nuts to the
specified torque.
Inspection Torque : 22 N·m (16 lb ft) for fan pulley and fan
Check drive belt for wear or damage, and replace with a bracket.
new one as necessary.
assembly.
NOTE: Fan belts for 6VE1 Gasoline Engine mounted on
98MY Trooper (UX) have been brought into one. As a
result, the rotating direction of a fan belt is opposite to the
direction of cooling fan for 92 to 97MY 6VD1 with no
interchangeability.
Therefore, incorrect installation of a fan may cause the air
for cooling to flow in the opposite direction, this resulting
in the poor performance of the air-conditioner and a rise
temperature in engine cooling water.

M/T A/T
Cooling system Engine coolant forced circulation
Radiator (1 tube in row) Tube type corrugated (2 tube in row)
Heat radiation capacity 68,000 kcal/h 77,000 kcal/h
Heat radiation area 9.445m@ (0.878ft@) 11.21m@ (1.04ft@)
Radiator front area 0.302m@ (0.028ft@)
Radiator dry weight 39N (8.8lb) 44N (9.9lb)
Radiator cap valve opening pressure 93.3 ∼ 122.7kpa (13.5 ∼ 17.8psi)
Engine coolant capacity 2.5lit (2.6U.S q.t.) 2.4lit (16.3U.S q.t.)
Engine coolant pump Centrifugal impeller type
Delivery 300 (317) or more
Pump speed 5000 ± 50 rpm
Thermostat Wax pellet type with air hole
Valve opening temperature 74.5 ∼ 78.5°C (166.1 ∼ 173.3°F)
Engine coolant total capacity 10.4lit (11.0U.S qt) 10.5lit (11.1U.S qt)
E06RW004
Special Tool
TOOL NO.
ILLUSTRATION
TOOL NAME
J–24460–01
Tester; radiator cap
J–33984–A
Adapter; radiator cap
ENGINE FUEL 6C–1
TROOPER
ENGINE
ENGINE FUEL
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 6C–1 Fuel Tank and Associated Parts . . . . . . . . . 6C–7
General Description . . . . . . . . . . . . . . . . . . . . . 6C–2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–7
Fuel Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–8
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–4 Fuel Tube / Quick – Connect Fittings . . . . . . . 6C–8
Fuel Filter and Associated Parts . . . . . . . . . 6C–4 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–8
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–4 Cautions During Work . . . . . . . . . . . . . . . . . . 6C–8
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–4 Reuse of Quick–Connector . . . . . . . . . . . . . . . 6C–10
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–5 Assembling Advice . . . . . . . . . . . . . . . . . . . . . . 6C–10
In–Tank Fuel Filter . . . . . . . . . . . . . . . . . . . . . 6C–5 Fuel Gauge Unit . . . . . . . . . . . . . . . . . . . . . . . . 6C–11
Fuel Pump Flow Test . . . . . . . . . . . . . . . . . . . 6C–5 Fuel Gauge Unit and Associated Parts . . . 6C–11
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–11
Fuel Pump and Associated Parts . . . . . . . . 6C–6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–6 Fuel Filler Cap . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–6 General Description . . . . . . . . . . . . . . . . . . . . . 6C–12
Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . . . 6C–7 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–12
General Description . . . . . . . . . . . . . . . . . . . . . 6C–7 Main Data and Specifications . . . . . . . . . . . . . 6C–12
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C–7

systems.
6C–2 ENGINE FUEL
General Description
140RY00002
Legend (8) Fuel Rail Left

(1) Fuel Filler Cap (9) Left Bank
(2) Fuel Tank (10) Fuel Pressure Control Valve
(3) Rollover Valve (11) Common Chamber
(4) Fuel Pump (Fuel Level Sending Unit/Fuel Tank (12) Duty Solenoid Valve
Pressure Sensor) (13) Throttle Valve
(5) Fuel Filter (14) Canister
(6) Fuel Rail Right (15) Evaporation Shut Off Valve
(7) Right Bank (16) Vent Solenoid Cut Valve
When working on the fuel system, there are several D Replace all pipes with the same pipe and fittings that
things to keep in mind: were removed.
D Any time the fuel system is being worked on, D Clean and inspect “O” rings. Replace if required.
disconnect the negative battery cable except for D Always relieve the line pressure before servicing any
those tests where battery voltage is required. fuel system components.
D Always keep a dry chemical (Class B) fire D Do not attempt repairs on the fuel system until you
extinguisher near the work area. have read the instructions and checked the pictures
relating to that repair.
ENGINE FUEL 6C–3
D Adhere to all Notices and Cautions.
All gasoline engines are designed to use only unleaded
gasoline. Unleaded gasoline must be used for proper
emission control system operation.
Its use will also minimize spark plug fouling and extend
engine oil life. Using leaded gasoline can damage the
emission control system and could result in loss of
emission warranty coverage.
All cars are equipped with an Evaporative Emission
Control System. The purpose of the system is to minimize
the escape of fuel vapors to the atmosphere.
Fuel Metering
The Engine Control Module (ECM) is in complete control
of this fuel delivery system during normal driving
conditions.
The intake manifold function, like that of a diesel, is used
only to let air into the engine. The fuel is injected by
separate injectors that are mounted over the intake
manifold.
The Manifold Absolute Pressure (MAP) sensor measures
the changes in the intake manifold pressure which result
from engine load and speed changes, which the MAP
sensor converts to a voltage output.
This sensor generates the voltage to change
corresponding to the flow of the air drawn into the engine.
The changing voltage is transformed into an electric
signal and provided to the ECM.
With receipt of the signals sent from the MAP sensor,
Intake Air Temperature sensor and others, the ECM
determines an appropriate fuel injection pulse width
feeding such information to the fuel injector valves to
effect an appropriate air/fuel ratio.
The Multiport Fuel Injection system utilizes an injection
system where the injectors turn on at every crankshaft
revolution. The ECM controls the injector on time so that
the correct amount of fuel is metered depending on
driving conditions.
Two interchangeable “O” rings are used on the injector
that must be replaced when the injectors are removed.
The fuel rail is attached to the top of the intake manifold
and supplies fuel to all the injectors.
Fuel is recirculated through the rail continually while the
engine is running. This removes air and vapors from the
fuel as well as keeping the fuel cool during hot weather
operation.
The fuel pressure control valve that is mounted on the fuel
rail maintains a pressure differential across the injectors
under all operating conditions. It is accomplished by
controlling the amount of fuel that is recirculated back to
the fuel tank based on engine demand.
See Section “Driveability and Emission” for more
information and diagnosis.
6C–4 ENGINE FUEL
Fuel Filter
Fuel Filter and Associated Parts
041RW014
Legend (3) Fuel Filter Fixing Bolt

(1) Fuel Filler Cap (4) Fuel Filter
(2) Fuel Hose
Removal Inspection
CAUTION: When repair to the fuel system has been 1. Replace the fuel filter if the fuel leaks from fuel filter
completed, start engine and check the fuel system body or if the fuel filter body itself is damaged.
for loose connection or leakage. For the fuel system 2. Replace the filter if it is clogged with dirt or sediment.
diagnosis, see Section “Driveability and Emission”. 3. Check the drain of receive rubber and if it is clogged
1. Disconnect battery ground cable. with dust, clean it up with air.
2. Remove Fuel filler cap(1).
3. Disconnect fuel hoses(2) from fuel filter on both Installation
engine side and fuel tank side.
1. Install the fuel filter in the proper direction.
4. Fuel filter fixing bolt(3).
2. Install fuel filter holder fixing bolt.
D Remove the fuel filter fixing bolt(3) on fuel filter
holder.
5. Remove fuel filter(4).
ENGINE FUEL 6C–5
3. Connect fuel hoses on engine side(1) and fuel tank 4. Connect the pump relay terminals with a jumper
side(2). wire(1) as shown and start the fuel pump to measure
delivery.
041RW001
4. Install fuel filler cap 140RW002
5. Connect the battery ground cable. CAUTION: Never generate sparks when connecting
a jumper wire.
Inspection Delivery Delivery
After installation, start engine and check for fuel leakage. 15 seconds 0.38 liters minimum
In–Tank Fuel Filter If the measure value is out of standard, conduct the
The filter is located on the lower end of fuel pickup tube in pressure test.
the fuel tank. It prevents dirt from entering the fuel pipe Pressure test
and also stops water unless the filter is completely
For the pressure test to the fuel system, see Section 6E
submerged in the water. It is a self cleaning type, not
requiring scheduled maintenance. Excess water and “Fuel Control System”.
sediment in the tank restricts fuel supply to the engine,
resulting in engine stoppage. In such a case, the tank
must be cleaned thoroughly.
Fuel Pump Flow Test

If reduction of fuel supply is suspected, perform the
following checks:
1. Make sure that there is fuel in the tank.
2. With the engine running, check the fuel feed pipe and
hose from fuel tank to injector for evidence of
leakage. Retighten, if pipe or hose connection is
loose. Also, check pipes and hoses for squashing or
clogging.
3. Insert the hose from fuel feed pipe into a clean
container, and check for fuel pump flow rate.
6C–6 ENGINE FUEL
Fuel Pump
Fuel Pump and Associated Parts
035RW030
CAUTION: When repair to the fuel system has been 1. Install FP assembly(2).
completed, start engine and check the fuel system 2. Install fuel tank assembly(1). Refer to “Fuel Tank
for loose connection or leakage. For the fuel system Installation”.
diagnosis, see Section “Driveability and Emission”. 3. Fill the tank with fuel and tighten fuel filler cap.
1. Disconnect battery ground cable. 4. Connect battery ground cable.
2. Loosen fuel filler cap.
3. Drain fuel.
Tighten drain plug to the specified torque after
draining fuel.
Torque: 20 N·m (14 lb ft) — M8
4. Remove fuel tank assembly(1). Refer to “Fuel Tank
Removal” in this section.
5. Remove fuel pump (FP) assembly(2) fixing screws
and remove the FP assembly.
NOTE: After removing FP, cover fuel tank to prevent any
dust entering.
ENGINE FUEL 6C–7
Fuel Pump Relay

General Description When it is turned to “START” position, the Power Train
Control Module (PCM) receives the reference pulse from
In order to control the FP operation, the FP relay is the Ignition Control Module and it operates the relay,
provided. When the starter switch is turned to “ON” again causing the FP to feed fuel.
position, the FP relay operates the FP for 2 seconds.
Fuel Tank
Fuel Tank and Associated Parts
035RW032
Legend (4) Fuel Tank Wiring Connector

(1) Fender Liner (5) Evapo Fuel Hose
(2) Fuel Filler Hose and Air Breather Hose and (6) Fuel Feed Tube and Fuel Return
Evapo Hose Tube/Quick–Connect Fittings
(3) Undercover (7) Fuel Tank
Removal 3. Drain fuel.

CAUTION: When repair to the fuel system has been draining fuel.
completed, start engine and check the fuel system
for loose connection or leakage. For the fuel system Torque: 20 N·m (14 lb ft) — M8
diagnosis, see Section “Driveability and Emission”. 4. Remove fender liner (1) of wheel well on rear right
1. Disconnect battery ground cable. side.
2. Loosen fuel filler cap. 5. Fuel filler hose, air breather hose and evapo hose (2).
6. Remove undercover fixing bolts on both sides and
remove under cover(3).
6C–8 ENGINE FUEL
7. Disconnect two fuel tank wiring connectors(4) on D Install a flange on left side on the bracket from the
front right side of tank. bottom, and tighten bolts to the specified torque.
8. Disconnect evapo fuel hose(5). Torque: 36 N·m (27 lb ft)
9. Disconnect fuel feed tube and fuel return tube(6). 2. Connect fuel feed tube and fuel return tube(6).
NOTE: Handling of the fuel tube, be sure to refer “Fuel 3. Connect evapo fuel hose(5).
Tube/Quick–Connect Fittings” in this section. 4. Connect fuel tank wiring connector(4).
10. Remove fuel tank fixing bolts on both sides and 5. Install undercover(3).
remove fuel tank(7). 6. Connect fuel filler hose, air breather hose and evapo
hose(2).
Installation 7. Install fender liner(1).
1. Install fuel tank(7). D Mount fender liner to the wheel well.
D Place a flange on right side of tank on the bracket. D Fill the tank with fuel and tighten fuel filler cap.
D Connect battery ground cable.
Fuel Tube / Quick – Connect Fittings

Precautions
D Lighting of Fires Prohibited.
D Keep flames away from your work area to prevent the
inflammable from catching fire.
D Disconnect the battery negative cable to prevent
shorting during work.
D When welding or conducting other heat-generating
work on other parts, be sure to provide pretreatment
to protect the piping system from thermal damage or
spattering.
Cautions During Work
Do not expose the assembly to battery electrolyte or do
not wipe the assembly with a cloth used to wipe off spilt
battery electorolyte.
The piping wet with battery electrolyte cannot be used.
Be careful not to give a bending or twisting force to the
piping during the work. If deformed, replace with a new
piping. 141RW016
As some pressure may remain in the piping, cover the

connector with a cloth, etc. to prevent the splashing
Removal of fuel in the first disconnection of the piping.
1. Open the fuel cap to relieve the fuel pressure in the
tank.
If the fuel quick-connect fittings are dusty, clean with
an air blower, etc. and then remove it.
ENGINE FUEL 6C–9
2. For removal of the delivery pipe (feeding fuel to the NOTE: This work should be done by hands. Do not use
engine), hold the connector in one hand, and hold the any tools. Should the pipe can hardly be removed from
retainer tab with the other hand and pull out the the connector, use a lubricant (light oil) and/or push and
connector, as illustrated. The pipe can be removed pull the connector longitudinally until the pipe is removed.
with the retainer attached.
141RW021
141RW019 When reusing the delivery pipe retainer, reuse

3. For removal of the return pipe (returnig fuel to the without removing the retainer from the pipe. If the
tank), hold the pipe in one hand, and pull out the retainer is damaged or deformed, however, replace
connentor with the other hand while pressing the with a new retainer.
square relieve button of the retainer, as illustrated. Cover the connectors removed with a plastic bag, etc.
to prevent the entry of dust or rain water.
141RW020
141RW022
6C–10 ENGINE FUEL
Reuse of Quick–Connector
(Delivery Pipe)
D Replace the pipe and connector if scratch, dent or
crack is found.
D Remove mud and dust from the pipe and make sure
that the end including spool is free of defects, such as
scratch, rust, and dent, which may cause poor
sealability. If defective, replace with a new pipe.
D If the retainer removed according to the removal step
above is attached to the pipe, clean and insert it
straight into the quick-connector till it clicks. After it
clicks, try pulling it out to make sure that it is not drawn
and is securely locked.
NOTE: The retainer, once removed from the pipe, cannot
be reused. Just replace with a new retainer. Insert the
new retainer into the connector side until it clicks, and
connect the pipe as inserting it into the retainer until it
clicks. 141RW017
Assembling Advice
Application of engine oil or light oil to the pipe facilitates
connecting work. The work should be started immediately
after lubrication, since dust may stick to the pipe surface
to cause poor sealability if a long time passes after
lubrication.
Test/Inspection After Assembling
1. Reconnect the battery negative cable.
2. Turn the ignition key to the “ON” position and check
pump startup sound. As the pump is actuated to raise
fuel pressure, check and see fuel leak from the piping
system.
3. Make sure of no fuel leakage by conducting the above
fuel leak check a few times.
4. Start the engine and make sure of stable idling speed
and normal vehicle run.The entry of dust during the
work may sometimes affect the fuel injection system.
141RW018
(Return Pipe)
D Replace the pipe and connector if scratch, dent or
crack is found.
D Remove mud or dust from the pipe and make sure
that the end including spool is free from defects, such
as scratch, rust, and dent, which may cause poor
sealability. If defective, replace with a new pipe.
D After cleaning the pipe, insert it straight into the
connector until it clicks. After it clicks, try pulling it out
to make sure that it is not drawn and is securely
locked.
ENGINE FUEL 6C–11
Fuel Gauge Unit

Fuel Gauge Unit and Associated Parts
140RS004
Legend
(1) Wiring Connector
(2) Fuel Gauge Unit
CAUTION: When repair to the fuel system has been 1. Fuel gauge unit(2).
completed, start engine and check the fuel system 2. Wiring connector(1).
for loose connection or leakage. For the fuel system D Connect the wiring connector to the fuel gauge unit.
diagnosis, see Section “Driveability and Emission”.
D Fill the tank with fuel and tighten fuel filler cap.
2. Loosen fuel filler cap. D Connect battery ground cable.
3. Drain fuel.
draining fuel.
Torque: 20 N·m (14 lb ft) — M8
4. Wiring connector
D Disconnect wiring connector(1) from the unit.
5. Fuel gauge unit
D Remove the fixing screws, then the fuel gauge
unit(2).
NOTE: After removing fuel gauge unit, cover fuel tank to
prevent any dust entering
6C–12 ENGINE FUEL
Fuel Filler Cap

General Description Legend
(1) Vacuum Valve
Fuel filler cap includes vacuum valve and pressure valve.
(2) Pressure Valve
In case any high vacuum and any high pressure happen in
tank, each valve works to adjust the pressure to prevent
the tank from being damaged.
Inspection
Check the seal ring in the filler cap for presence of any
abnormality and for seal condition.
Replace the filler cap, if abnormal.
CAUTION: The fuel filler cap valves have
characteristics.
A defective valve, no valve at all or a valve with the
wrong characteristics will do a lot of harm to engine
operating characteristics; be sure to use the same
fuel filler cap as installed in this vehicle.
140RW021

035RW031
ENGINE ELECTRICAL 6D1–1
TROOPER
ENGINE
ENGINE ELECTRICAL
CONTENTS
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D1–1 Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . 6D1–2
General Description . . . . . . . . . . . . . . . . . . . . 6D1–1 Battery Removal . . . . . . . . . . . . . . . . . . . . . . 6D1–3
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D1–1 Battery Installation . . . . . . . . . . . . . . . . . . . . . 6D1–3
Battery Charging . . . . . . . . . . . . . . . . . . . . . . 6D1–2 Main Data and Specifications . . . . . . . . . . . 6D1–4
Battery
General Description
There are six battery fluid caps on top of the battery.
These are covered by a paper label.
The battery is completely sealed except for the six small
vent holes on the side. These vent holes permit the
escape of small amounts of gas generated by the battery.
This type of battery has the following advantages over
conventional batteries:
1. There is no need to add water during the entire
service life of the battery.
2. The battery protects itself against overcharging.
The battery will refuse to accept an extensive charge.
(A conventional battery will accept an excessive
charge, resulting in gassing and loss of battery fluid.)
3. The battery is much less vulnerable to self discharge
than a conventional type battery.
Diagnosis
061RW001
1. Visual Inspection
Inspect the battery for obvious physical damage, such as
a cracked or broken case, which would permit electrolyte
loss.
Replace the battery if obvious physical damage is
discovered during inspection.
Check for any other physical damage and correct it as
necessary.
2. Hydrometer Check
There is a built–in hydrometer (Charge test indicator(1))
at the top of the battery. It is designed to be used during
diagnostic procedures.
Before trying to read the hydrometer, carefully clean the
upper battery surface.
If your work area is poorly lit, additional light may be
necessary to read the hydrometer.
a. BLUE RING OR DOT VISIBLE(5) – Go to Step 4.
b. BLUE RING OR DOT NOT VISIBLE(4) – Go to Step
3.
6D1–2 ENGINE ELECTRICAL
3. Fluid Level Check a. VOLTAGE DOES NOT DROP BELOW THE
The fluid level should be between the upper level line(2) MINIMUM LISTED IN THE TABLE – The battery is
good and should be returned to service.
and lower level line(3) on side of battery.
a. CORRECT FLUID LEVEL – Charge the battery. b. VOLTAGE IS LESS THAN MINIMUM LISTED –
Replace battery.
b. BELOW LOWER LEVEL – Replace battery.
ESTIMATED TEMPERATURE MINIMUM
VOLTAGE
°F °C V
70 21 9.6
60 16 9.5
50 10 9.4
40 4 9.3
30 –1 9.1
20 –7 8.9
10 –12 8.7
0 –18 8.5
The battery temperature must be estimated by feel
and by the temperature the battery has been
exposed to for the preceding few hours.
061RW001
4. Voltage Check Battery Charging

1. Put voltmeter test leads to battery terminals. Observe the following safety precautions when charging
a. VOLTAGE IS 12.4V OR ABOVE – Go to Step 5. the battery:
b. VOLTAGE IS UNDER 12.4V – Go to procedure (2) 1. Never attempt to charge the battery when the fluid
below. level is below the lower level line on the side of the
battery. In this case, the battery must be replaced.
2. Determine fast charge amperage from specification.
(See Main Data and Specifications in this section). 2. Pay close attention to the battery during charging
procedure.
Fast charge battery for 30 minutes at amperage rate
no higher than specified value. Battery charging should be discontinued or the rate of
charge reduced if the battery feels hot to the touch.
Take voltage and amperage readings after charge.
Battery charging should be discontinued or the rate of
a. VOLTAGE IS ABOVE 16V AT BELOW 1/3 OF charge reduced if the battery begins to gas or spew
AMPERAGE RATE – Replace battery. electrolyte from the vent holes.
b. VOLTAGE IS ABOVE 16V AT ABOVE 1/3 OF 3. In order to more easily view the hydrometer blue dot
AMPERAGE RATE – Drop charging voltage to or ring, it may be necessary to jiggle or tilt the battery.
15V and charge for 10 – 15 hours. Then go to Step
5. 4. Battery temperature can have a great effect on
battery charging capacity.
c. VOLTAGE IS BETWEEN 12V AND 16V –
Continue charging at the same rate for an 5. The sealed battery used on this vehicle may be either
additional 3–1/2 hours. Then go to Step 5. quick charged or slow charged in the same manner as
other batteries.
d. VOLTAGE BELOW 12V – Replace Battery.
Whichever method you decide to use, be sure that
you completely charge the battery. Never partially
5. Load Test charge the battery.
1. Connect a voltmeter and a battery load tester across
the battery terminals.
2. Apply 300 ampere load for 15 seconds to remove
Jump Starting
surface charge from the battery. Remove load. Jump Starting with an Auxiliary (Booster)
3. Wait 15 seconds to let battery recover. Then apply Battery
specified load from specifications (See Main Data
and Specifications in this section). CAUTION: Never push or tow the vehicle in an
Read voltage after 15 seconds, then remove load. attempt to start it. Serious damage to the emission
system as well as other vehicle parts will result.
ENGINE ELECTRICAL 6D1–3
Treat both the discharged battery and the booster 4. Attach one end of the remaining cable to the negative
battery with great care when using jumper cables. terminal of the booster battery.
Carefully follow the jump starting procedure, being Attach the other end of the same cable to a solid
careful at all times to avoid sparking. engine ground (such as the air conditioning
WARNING: FAILURE TO CAREFULLY FOLLOW THE compressor bracket or the generator mounting
JUMP STARTING PROCEDURE COULD RESULT IN bracket) of the vehicle with the discharged battery.
THE FOLLOWING: The ground connection must be at least 450 mm (18
in.) from the battery of the vehicle whose battery is
1. Serous personal injury, particularly to your eyes. being charged.
2. Property damage from a battery explosion, battery
acid, or an electrical fire. WARNING: NEVER ATTACH THE END OF THE
JUMPER CABLE DIRECTLY TO THE NEGATIVE
3. Damage to the electronic components of one or both
TERMINAL OF THE DEAD BATTERY.
vehicles particularly.
Never expose the battery to an open flame or electrical 5. Start the engine of the vehicle with the good battery.
spark. Gas generated by the battery may catch fire or Make sure that all unnecessary electrical accessories
explode. have been turned “OFF”.
Remove any rings, watches, or other jewelry before 6. Start the engine of the vehicle with the dead battery.
working around the battery. Protect your eyes by wearing
7. To remove the jumper cables, follow the above
an approved set of goggles. directions in reverse order.
Never allow battery fluid to come in contact with your eyes
Be sure to first disconnect the negative cable from the
or skin. vehicle with the discharged battery.
Never allow battery fluid to come in contact with fabrics or
painted surfaces.
Battery fluid is a highly corrosive acid. Battery Removal
Should battery fluid come in contact with your eyes, skin,
fabric, or a painted surface, immediately and thoroughly
rinse the affected area with clean tap water.
Never allow metal tools or jumper cables to come in
contact with the positive battery terminal, or any other
metal surface of the vehicle. This will protect against a
short circuit.
Always keep batteries out of reach of young children.
Jump Starting Procedure

1. Set the vehicle parking brake.
If the vehicle is equipped with an automatic
transmission, place the selector level in the “PARK”
position.
If the vehicle is equipped with a manual transmission,
place the shift lever in the “NEUTRAL” position.
Turn “OFF” the ignition.
Turn “OFF” all lights and any other accessory
requiring electrical power.
061RS002
2. Look at the built–in hydrometer. 1. Remove negative cable (1).

If the indication area of the built–in hydrometer is 2. Remove positive cable (2).
completely clear, do not try to jump start.
3. Remove retainer screw and rods (3).
3. Attach the end of one jumper cable to the positive
terminal of the booster battery. 4. Remove retainer (4).
Attach the other end of the same cable to the positive 5. Remove battery (5).
terminal of the discharged battery.
Do not allow the vehicles to touch each other. This will Battery Installation
cause a ground connection, effectively neutralizing
the charging procedure. 1. Install battery (5).
Be sure that the booster battery has a 12 volt rating. 2. Install retainer (4).
3. Instal retainer screw and rods (3).
NOTE: Make sure that the rod is hooked on the body
side.
4. Install positive cable (2).
5. Install negative cable (1).
6D1–4 ENGINE ELECTRICAL

Model (JIS) 95D31R–MF 80D26R–MF 75D26R–MF
Voltage (V) 12 12 12
Cold Cranking Performance (Amp) 622 582 490
Reserve Capacity (Min) 159 133 123
Load Test (Amp) 310 290 245
Fast Charge Maximum Amperage (Amp) 20 20 20
BCI Group No. 27 24 24
IGNITION SYSTEM 6D2–1
TROOPER
ENGINE
IGNITION SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 6D2–1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D2–5
General Description . . . . . . . . . . . . . . . . . . . . . 6D2–2 Inspection and Repair . . . . . . . . . . . . . . . . . . 6D2–5
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D2–2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D2–5
Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D2–3 Crankshaft Position Sensor . . . . . . . . . . . . . . . 6D2–6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D2–3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D2–6
Inspection and Repair . . . . . . . . . . . . . . . . . . 6D2–3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D2–6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D2–3 Main Data and Specifications . . . . . . . . . . . . . 6D2–7
Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D2–5

systems.
6D2–2 IGNITION SYSTEM
General Description
Ignition is done by the electronic ignition (El) that directly The ignition coils are connected with the PCM by means
fires the spark plugs from ignition coils through spark plug of a 80 pin connector.
wires without using a distributor. A pair of ignition coils for The ignition control module turns on/off the primary circuit
the cylinders having different phases by 360° (No.1 and of ignition coils, and also it controls the ignition timing at
No.4,No.2 and No.5,No.3 and No.6) are fired the engine speed below 538 rpm.
simultaneously. A notch in the timing disc on the crankshaft activates the
Since the cylinder on exhaust stroke requires less energy crank position sensor which then sends information such
to fire its ignition plug, energy from the ignition coils can be as firing order and starting timing of each ignition coil to
utilized to fire the mating cylinder on compression stroke. the PCM.
After additional 360° rotation, respective cylinder strokes Further, the El employs ignition control (IC) to control
are reversed. similar to a distributor system.
The EI consists of six ignition coils,ignition control By receiving signals such as crank position,engine
module, position angle sensor, powertrain control module speed, water temperature and Manifold Absolute
(PCM) and other components. Pressure (MAP), the PCM controls the ignition timing.
D06RY00037
Diagnosis
Refer to Section Drivability and Emissions for the
diagnosis to electronic ignition system (El system).
Ignition Coil
Removal Measure resistance of ignition coil assembly, and replace
the ignition coil assembly if its value exceeds the
1. Disconnect battery ground cable. standard.
2. Ignition coil connector and ignition coil.
D Disconnect three connector from ignition coil.
D Remove harness bracket bolt on cylinder head
cover.
D Remove fixing bolts on ignition coil.
060RW006
Installation
1. Install the ignition coil assembly (3).
Connect ignition coil connector (1) and ignition coil
060RY023
(3), then tighten bolt (2) to the specified torque.
Legend Torque: 4 N·m (35.4 lb in)
(2) Bolt
(3) Ignition Coil Assembly

Check the ignition coil assembly for insulation. Check
terminals for corrosion or damage, and replace as
necessary.
Measuring resistance of ignition coil assembly.
Terminal No. Limit
1 to 2 Resistance cannot be 0
ohm (short) or infinity
(open circuit).
1 to 3 Same as above
2 to 3 Same as above
060RY023
CAUTION: Ignition coil assembly # 6 is different
from ignition coil assembly from # 1 to # 5. Ignition
coil assembly # 6 is short type. So, note it when
installing ignition coil assembly of # 6.
060RY00002
Legend
(1) Long Type Ignition Coil Assemblies (# 1 ∼ # 5)
(2) Short Type Ignition Coil Assembly (# 6)

Spark Plug
Removal
1. Remove spark plugs.

The spark plug affects entire engine performance and
therefore its inspection is very important.
D Check electrode and insulator for presence of cracks,
and replace if any.
D Check electrode for wear, and replace if necessary.
D Check gasket for damage, and replace if necessary.
D Measure insulation resistance with an ohmmeter, and
replace if faulty.
D Adjust spark plug gap to 1.0 mm (0.04 in) ∼ 1.1 mm
(0.043 in).
D Check fuel and electrical systems if spark plug is
extremely dirty.
D Use spark plugs having low heat value (hot type plug) 011RS010
if fuel and electrical systems are normal.

D Use spark plugs having high heat value (cold type
Cleaning Spark Plugs
plug) if insulator and electrode are extremely burned. D Clean spark plugs with a spark plug cleaner.
Sooty Spark Plugs D Raise the ground electrode to an angle of 45 to 60
degrees. If electrode is wet, dry it before cleaning.
Much deposit of carbon or oil on the electrode and
insulator of spark plug reduces the engine performance. D After spark plug is thoroughly cleaned, check
insulator for presence of cracks.
Possible causes:
D Clean threads and metal body with a wire brush.
D Too rich mixture D File the electrode tip if electrode is extremely worn.
D Presence of oil in combustion chamber D Bend the ground electrode to adjust the spark plug
D Incorrectly adjusted spark plug gap gap.
Burning Electrodes
This fault is characterized by scorched or heavily oxidized
electrode or blistered insulator nose.
Possible causes:
D Too lean mixture
D Improper heat value
Measuring Insulation Resistance

D Measure insulation resistance using a 500 volt
megaohm meter.
D Replace spark plugs if measured value is out of
standard.
Insulation resistance: 50 MW or more
011RS011
Installation
1. Spark plugs
D Tighten spark plugs to the specified torque.
Crankshaft Position Sensor

Removal
1. Disconnect battery ground cable
2. Wiring connector from crankshaft position sensor.
3. Remove crankshaft position sensor from cylinder
block.
012RS008
Installation
1. Install crankshaft position sensor into the cylinder
block.
Before installation,apply small amount of engine oil to
the O–ring.
2. Reconnect wiring connector to crankshaft position
sensor.

Ignition System
Ignition Form Electronic Ignition System (El system) with Crankshaft position Sensor
Spark Plug
Type K16PR–P11
RC10PYP4
PK16PR11
Plug gap 1.0 mm (0.04 in) – 1.1 mm (0.043 in)
Torque 18 N·m (13 lb ft)
E06RY001
STARTING AND CHARGING SYSTEM 6D3–1
TROOPER
ENGINE
STARTING AND CHARGING SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 6D3–1 General Description . . . . . . . . . . . . . . . . . . . . . 6D3–18
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . 6D3–2 General On–Vehicle Inspection . . . . . . . . . . . 6D3–18
General Description . . . . . . . . . . . . . . . . . . . . . 6D3–2 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3–19
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3–4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3–19
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3–5 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3–19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3–5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3–19
Disassembled View . . . . . . . . . . . . . . . . . . . . 6D3–6 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3–21
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3–7 Inspection and Repair . . . . . . . . . . . . . . . . . . 6D3–23
Inspection and Repair . . . . . . . . . . . . . . . . . . 6D3–9 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3–25
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3–13 Bench Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3–25
Main Data and Specifications . . . . . . . . . . . 6D3–15 Main Data and Specifications . . . . . . . . . . . 6D3–26
Charging System . . . . . . . . . . . . . . . . . . . . . . . . 6D3–18

systems.
6D3–2 STARTING AND CHARGING SYSTEM
Starting System
General Description
Cranking Circuit
The cranking system consists of a battery, starter, starter
switch, starter relay, etc. These main components are
connected.
Starter
The cranking system employs a magnetic type reduction
starter in which the motor shaft is also used as a pinion
shaft. When the starter switch is turned on, the contacts of
magnetic switch are closed, and the armature rotates. At
the same time, the plunger is attracted, and the pinion is
pushed forward by the shift lever to mesh with the ring
gear.
Then, the ring gear runs to start the engine. When the
engine starts and the starter switch is turned off, the
plunger returns, the pinion is disengaged from the ring
gear, and the armature stops rotation. When the engine
speed is higher than the pinion, the pinion idles, so that
the armature is not driven.
C06RY00002
Diagnosis
Starter does not run Charging failure Repair charging system
Battery Failure Replace Battery
Terminal connection failure Repair or replace terminal connector
and/or wiring harness
Starter switch failure Repair or replace starter switch
Starter failure Repair or replace starter
Starter
Removal 2. Install mounting bolts and tighten bolts to specified
torque(5).
1. Battery ground cable.
2. Disconnect Heated O2 Sensor connector (1).
3. Reconnect the connectors to terminals “B” and “S”
3. Remove exhaust front left pipe(2). and tighten Terminals “B” to specified torque.
4. Install heat protector(3).
035RW016
4. Remove heat protector(3).

5. Disconnect starter wiring connector from terminals
“B” and “S”(4). 065RW027
6. Remove starter assembly mounting bolts on inside 5. Install exhaust front left pipe and tighten bolts and
and outside(5). nuts to specified torque(2).
7. Remove starter assembly toward the bottom of Stud Nuts
engine(6). Torque: 67 N·m (49 lb ft)
Nuts
6. Connect Heated O2 Sensor connector (1).
065RW027
Installation
1. Install starter assembly(6). 035RW016
7. Reconnect the battery ground cable.

Disassembled View
065RW002
Legend (14) Center Bracket

(1) Bolt (2 pcs) (15) Pinion Shaft
(2) Ball Bearing (16) Planet Gear (3)
(3) Pinion (17) Internal Gear
(4) Shift Lever (18) Center Bracket (A)
(5) Dust Cover (19) Yoke Assembly
(6) Torsion Spring (20) Armature
(7) Dust Cover (21) Brush
(8) Magnetic Switch (22) Brush Holder
(9) Nut (23) Thrust Washer
(10) Gear Case (24) Rear Cover
(11) Bearing Cover (25) Screw (2 pcs)
(12) E–Ring (26) Through Bolt (2 pcs)
(13) Thrust Washer (2)
Disassembly 7. Remove screw (2 pcs) (8).

8. Remove through bolt (2 pcs) (7).
1. Loosen the nut(1) on terminal “M” of magnetic switch
and disconnect the connector cable. 9. Remove screws and through bolts, then the rear
cover(9) then remove thrust washer(10).
2. Remove bolt (2 pcs) (2).
10. Remove brush holder(6).
065RW003
3. Remove magnetic switch(5). 065RW005
11. Raise a brush spring to detach brushes (4 pcs) from

4. Remove dust cover(4). the commutator face and pull off the brush holder(12)
5. Remove torsion spring bolts, then the magnetic and brush(11).
switch assembly.
6. Remove torsion spring(3) from magnetic switch
assembly(5).
065RW006
065RW004
12. Remove yoke assembly(14). 17. Remove ball bearing(19).
13. Remove armature(15). 18. Remove bearing cover(20).
14. Pull off the yoke assembly, then remove armature, 19. Remove a ball bearing and bearing cover from the
washer and center bracket.(A) (13). gear case(18).
NOTE: In disassembling the yoke assembly, hold the
armature and pull off slowly the yoke assembly. Because
of strong magnetic force, avoid placing a metallic part
near armature.
065RW021
20. Internal gear(21).

21. Remove internal gear and planet gear(3) (22).
065RW007
15. Remove dust cover(17).

16. Remove a dust cover and shift lever(16) from the gear
case.
065RW009
065RW008
22. Remove an E–ring(23) from the pinion shaft using a Inspection and Repair
flat blade screwdriver.
Repair or replace necessary parts if extreme wear or
damage is found during inspection.
Armature
Measure the outer diameter of commutator, and replace
with a new one if it is out of the limit.
Limit: 32.0 mm (1.26 in)
065RW010
23. Holding the pinion shaft, push pinion toward the

center bracket. and turn the pinion clockwise or
counterclockwise by one tooth of spline, then pull off
the pinion.
24. Remove thrust washer(24).
25. Remove center bracket
26. Remove pinion shaft. 065RS014
Check for continuity between commutator and segment.

Replace commutator if there is no continuity (i.e.,
disconnected).
065RW011
065RS015
Check for continuity between commutator and shaft. Polish the commutator surface with sandpaper #500 to
Also, check for continuity between commutator and #600 if it is rough.
armature core,armature core and shaft. Replace
commutator if there is continuity (i.e., internally
grounded).
065RW012
Measure the depth of insulator in commutator. Repair, if it

is below the limit.
065RS016 Standard: 0.5 mm to 0.8 mm (0.02 in to 0.03 in)
Measure runout of armature core and commutator with a Limit: 0.2 mm (0.008 in)
dial gauge. Repair or replace, if it exceeds the limit.
Armature
Standard: 0.05 mm (0.002 in) Max.
Limit: 0.10 mm (0.004 in)
Commutator
Standard: 0.05 mm (0.002 in) Max.
Limit: 0.10 mm (0.004 in)
065RW013
Legend
(1) Steel Saw
(2) Insulator
(3) Commutator Segments
065RS017
Brush Magnetic Switch
Measure the length of brush. Check for continuity of shunt coil between terminals S and
Replace with a new one, if it is below the limit. M.
Standard: 16 mm (0.63 in) Replace, if there is no continuity (i.e., coil is
Limit: 11 mm (0.43 in) disconnected).
065RW016
065RW014
Brush Holder Continuity of Series Coil

Check for continuity between brush holder (+) (4) and Check for continuity between terminals S and M.
base (–). Replace, if there is continuity (i.e., insulation is Replace, if there is no continuity (i.e., coil is
broken). disconnected).
065RW017
065RW015
Continuity of Contacts Yoke Assembly
With the plunger faced downward, push down the Check a magnet inside the yoke.
magnetic switch. In this state, check for continuity Replace the yoke assembly if it is broken.
between terminals B and M. Replace, if there is no
continuity (i.e., contacts are faulty).
065RS026
065RW018
Ball Bearing
Clamp the inner race of the ball bearing with your finger,
Pinion and check for sticking or play when rotating the outer
Check if the pinion rotates smoothly in drive direction by race.
hand, or if it is locked when it is rotated in reverse. If not, Replace, if abnormality is found.
replace the pinion.
065RS027
065RS025
Measure inner diameter of bushing in the rear cover, and Reassembly
replace if it exceeds the limit.
Standard: 12.50 mm to 12.527 mm (0.492 in to noting the following points:
0.4932 in)
Grease application places
Limit: 12.60 mm (0.4961 in)
D Bushing in rear cover and center bracket
D Gears in reduction gear
D Shift lever operating portion
D Sliding portion of pinion
D Plunger sliding portion of magnetic switch
Reassembling Yoke Assembly
Before reassembly, make sure that no metallic parts
attach to the yoke assembly. Because of strong magnetic
force, hold the yoke assembly and insert it slowly into the
armature.
Torque
Torque for each part (See Torque Specifications in
this section)
Pinion Jump–out Dimension

Connect the “+” cable of battery to terminal S and the “–”
cable to terminal M. Turn the switch on, and measure
065RS028
pinion travel dimension in thrust direction from the
Measure inner diameter of bushing in the center bracket jump–out position.
(P), and replace if it exceeds the limit. In measuring the dimension, pull the pinion out a little in
Standard: 18.01 mm to 18.127 mm (0.7091 in to the arrow direction.
0.7137 in) Dimension(L): 0.05 mm to 1.5 mm (0.002 in to
Limit: 18.15 mm (0.7146 in) 0.06 in)
065RS029 065RS030
If the measured value is out of standard, insert dust cover,
or disassemble and adjust.
065RW019
Characteristic Test
For easily confirming the characteristics, conduct the no
load test as follows:
Rating as short as 30 seconds requires rapid testing.
Fix the starter on the test bench, and wire as shown in
illustration. When the switch is closed, the current flows
and the starter runs under no load. At this time, measure
current, voltage and speed to check if they satisfy the
standard.
065RW020
Legend
(1) Volt Meter
(2) Tachometer
(3) Battery
(4) Ammeter
(5) Switch

Model HITACHI GD003138
Rating
Voltage 12 V
Output 1.4 Kw
Time 30 sec
Number of teeth of pinion 9
Rotating direction(as viewed from pinion) Clockwise
Weight(approx.) 34 N
No load characteristics
Voltage /Current 11V/90A or less
Speed 2700rpm or more
Load characteristics
Voltage/current 8.4V/250A
Torque 7.3N·m(64lb·in.) or more
Speed 1200rpm or more
Locking characteristics
Voltage/current 3V/750A or less
Torque 19N·m(14lb·in) or more
E06RW023
E06RW024
Charging System
General Description General On–Vehicle Inspection
The IC integral regulator charging system and its main The operating condition of charging system is indicated
components are connected as shown in the illustration. by the charge warning lamp. The warning lamp comes on
The regulator is a solid state type and it is mounted along when the starter switch is turned to “ON” position. The
with the brush holder assembly inside the generator charging system operates normally if the lamp goes off
installed on the rear end cover. when the engine starts.
The generator does not require particular maintenance If the warning lamp shows abnormality or if undercharged
such as voltage adjustment. or overcharged battery condition is suspected, perform
The rectifier connected to the stator coil has eight diodes diagnosis by checking the charging system as follows:
to transform AC voltage into DC voltage. 1. Check visually the belt and wiring connector.
This DC voltage is connected to the output terminal of 2. With the engine stopped, turn the stator switch to
generator. “ON” position and observe the warning lamp.
If lamp does not come on:
Disconnect wiring connector from generator, and
ground the terminal “L” on connector side.
If lamp comes on:
Repair or replace the generator.
F06RY00002
Generator
Removal
2. Move drive belt tensioner to loose side using wrench
then remove drive belt (1).
3. Disconnect the wire from terminal “B” and disconnect
the connector (4).
4. Remove generator fixing bolt (3).
5. Remove generator assembly (2).
066RW001
If voltage is not present, the line between battery and

connector is disconnected and so requires repair.
3. Reconnect the wiring connector to the generator, run
the engine at middle speed, and turn off all electrical
devices other than engine.
4. Measure battery voltage. If it exceeds 16V, repair or
replace the generator.
5. Connect an ammeter to output terminal of generator,
and measure output current under load by turning on
060RW002
the other electrical devices (eg., head lights). At this
time, the voltage must not be less than 13V.
Inspection
1. Disconnect the wiring connector from generator. Installation
2. With the engine stopped, turn starter switch to “ON”
1. Install generator assembly to the position to be
and connect a voltmeter between connector terminal
installed.
L (2) and ground or between terminal IG (1) and
ground. 2. Install generator assembly and tighten the fixing bolts
Torque:
M10 bolt: 41 N·m (30 lb ft)
M8 bolt: 21 N·m (15 lb ft)
3. Connect wiring harness connector and direct terminal
“B”.
5. Reconnect battery ground cable.
Disassembled View
066RW007
Legend (6) Rectifier

(1) Pulley Nut (7) Terminal Insulator and Nut
(2) Pulley (8) Regulator Assembly
(3) Front Cover Assembly (9) Brush Holder Assembly
(4) Rotor Assembly (10) Rear Cover
(5) Rear End Cover
Disassembly 4. Remove three screws on the IC regulator, then the IC

regulator assembly(6).
1. Terminal insulator and nut(2).
2. Remove three nuts(1) on the rear cover and a nut on
terminal B and insulator, then remove the rear
cover(3).
060RW003
5. Remove four screws that fix rectifier(7) and stator

lead wires.
060RW005
3. Remove two screws that fix the brush holder(5) and

rectifier, then remove the brush holder assembly(4).
066RW004
060RW004
6. Secure the pulley directly in the vise between two 8. Use the puller to remove the rear end cover.
copper plates, and remove the nut and pulley. 9. Rotor assembly
066RS010
066RS012
7. Remove four nuts(8) that secure the front cover 10. Pull the rotor assembly(10) off the front cover
assembly and rear end cover, and an insulator(9). assembly(12) using a bench press(11).
066RW005
066RW006
Inspection and Repair 3. Check resistance between slip rings, and replace if
there is no continuity.
Repair or replace necessary parts if extreme wear or
damage is found during inspection.
Rotor Assembly
1. Check the rotor slip ring surfaces for contamination
and roughness. If rough, polish with #500—600
sandpaper.
066RS016
4. Check for continuity between slip ring and rotor core.

In case of continuity, replace the rotor assembly.
066RS014
2. Measure the slip ring diameter, and replace if it

exceeds the limit.
066RS017
066RS015
Stator Coil Rectifier Assembly
1. Measure resistance between respective phases. Check for continuity across “P” and “E” in the × 100W
range of multimeter.
2. Measure insulation resistance between stator coil
and core with a mega–ohmmeter.
If less than standard, replace the coil.
066RW002
Change polarity, and make sure that there is continuity in

one direction, and not in the reverse direction. In case of
066RS018 continuity in both directions, replace the rectifier
assembly.
Brush
Measure the brush length. IC Regulator Assembly
If more than limit, replace the brush. Check for continuity across “B” and “F” in the × 100W
Standard: 10.mm (0.4134 in) range of multimeter.
Limit: 8.4.mm (0.3307 in)
066RS021
Change polarity, and make sure that there is continuity in

066RS019
one direction, and not in the reverse direction. In case of
continuity in both directions, replace the IC regulator
assembly.
Reassembly Bench Test

To reassemble, follow the disassembly steps in the Conduct a bench test of the generator.
reverse order, noting the following points:
1. Using a press with a socket wrench attached,
reassemble rotor and rear end cover assembly in the
front cover.
066RS023
Preparation
Remove generator from the vehicle (see “Generator
removal”).
066RS022
1. Secure generator to the bench test equipment and
2. Install pulley on the rotor.
connect wires.
Secure the pulley directly in the vise between two
Terminal “IG” for energization
copper plates, and tighten nut to the specified torque.
Terminal “L” for neutral (warning lamp)
Terminal “B” for output
2. Conduct the generator characteristic test.
Characteristics of generator are shown in illustration.
Repair or replace the generator if its outputs are
abnormal.
066RS010
B06RX001

Parts Number (Nippon denso) 102211—1740
Model ACJV74
Rated voltage 12 V
Rated output 90 A
Rotating direction (As viewed from pulled) Clockwise
Pulley effective diameter 57.5 mm (2.26 in)
Weight 49.7 N (11.2 lb)
TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS 6E–1
TROOPER
ENGINE
TROOPER 3.5L ENGINE DRIVEABILITY AND EMISSIONS
CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–6 Serial Data Communications . . . . . . . . . . . . . . 6E–39
Tightening Specifications . . . . . . . . . . . . . . . 6E–6 Class II Serial Data Communications . . . . . 6E–39
Diagrams and Schematics . . . . . . . . . . . . . . . . 6E–7 On-Board Diagnostic (OBD II) . . . . . . . . . . . . . 6E–39
PCM Wiring Diagram (1 of 7) . . . . . . . . . . . . 6E–7 On-Board Diagnostic Tests . . . . . . . . . . . . . 6E–39
PCM Wiring Diagram (2 of 7) . . . . . . . . . . . . 6E–8 Comprehensive Component Monitor
PCM Wiring Diagram (3 of 7) . . . . . . . . . . . . 6E–9 Diagnostic Operation . . . . . . . . . . . . . . . . . . 6E–39
PCM Wiring Diagram (4 of 7) . . . . . . . . . . . . 6E–10 System Status and Drive Cycle for
PCM Wiring Diagram (5 of 7) . . . . . . . . . . . . 6E–11 Satisfying Federal Inspection/Maintenance
PCM Wiring Diagram (6 of 7) . . . . . . . . . . . . 6E–12 (I/M 240) Regulations . . . . . . . . . . . . . . . . . . 6E–40
PCM Wiring Diagram (7 of 7) . . . . . . . . . . . . 6E–13 Common OBD II Terms . . . . . . . . . . . . . . . . . 6E–40
PCM Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–14 The Diagnostic Executive . . . . . . . . . . . . . . . 6E–40
PCM Pinout Table, 80-Way Blue DTC Types . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–41
Connector – Row “F1 ∼ 20” . . . . . . . . . . . . . 6E–14 Decimal/Binary/Hexadecimal Conversions 6E–43
PCM Pinout Table, 80-Way Blue Verifying Vehicle Repair . . . . . . . . . . . . . . . . 6E–43
Connector – Row “F20 ∼ 40” . . . . . . . . . . . 6E–16
Reading Diagnostic Trouble Codes Using
PCM Pinout Table, 80-Way Blue
Connector – Row “F41 ∼ 60” . . . . . . . . . . . 6E–18 The Tech 2 Scan Tool . . . . . . . . . . . . . . . . . 6E–43
PCM Pinout Table, 80-Way Blue Tech 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–44
Connector – Row “F61 ∼ 80” . . . . . . . . . . . 6E–20 Tech 2 Features . . . . . . . . . . . . . . . . . . . . . . . 6E–45
PCM Pinout Table, 80-Way Red Getting Started . . . . . . . . . . . . . . . . . . . . . . . . 6E–45
Connector – Row “S1 ∼ 20” . . . . . . . . . . . . 6E–22
PCM Pinout Table, 80-Way Red Operating Procedure (For Example) . . . . . 6E–46
Connector – Row “S21 ∼ 40” . . . . . . . . . . . 6E–24 DTC Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–47
PCM Pinout Table, 80-Way Red DTC Information Mode . . . . . . . . . . . . . . . . . 6E–47
Connector – Row “S41 ∼ 60” . . . . . . . . . . . 6E–26 Miscellaneous Test . . . . . . . . . . . . . . . . . . . . 6E–48
PCM Pinout Table, 80-Way Red
Connector – Row “S61 ∼ 80” . . . . . . . . . . . 6E–28 Lamps Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–48
Component Locators . . . . . . . . . . . . . . . . . . . 6E–30 Relays Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–50
Engine Component Locator Table . . . . . . . . 6E–31 EVAP Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–51
Undercarriage Component Locator . . . . . . 6E–32 Fuel System Test . . . . . . . . . . . . . . . . . . . . . . 6E–52
Undercarriage Component Locator Table . 6E–32 Instruments Test . . . . . . . . . . . . . . . . . . . . . . . 6E–54
Fuse and Relay Panel (Underhood EGR Control Test . . . . . . . . . . . . . . . . . . . . . . 6E–56
Electrical Center) . . . . . . . . . . . . . . . . . . . . . 6E–33 Variable Intake Manifold Solenoid Test . . . 6E–56
Sensors and Miscellaneous Component Injector Balance Test . . . . . . . . . . . . . . . . . . . 6E–58
Locators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–34
Plottong Snapshot Graph . . . . . . . . . . . . . . . . . 6E–58
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–37
Plotting Graph Flow Chart (Plotting graph
Strategy-Based Diagnostics . . . . . . . . . . . . . 6E–37 after obtaining vehicle information) . . . . . . 6E–59
Strategy-Based Diagnostics . . . . . . . . . . . . . 6E–37 Flow Chart for Snapshot Replay
DTC Stored . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–37 (Plotting Graph) . . . . . . . . . . . . . . . . . . . . . . . 6E–60
No DTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–37 Primary System-Based Diagnostic . . . . . . . . . 6E–61
No Matching Symptom . . . . . . . . . . . . . . . . . 6E–37 Primary System-Based Diagnostic . . . . . . . 6E–61
Intermittents . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–37 Fuel Control Heated Oxygen Sensor . . . . . 6E–61
No Trouble Found . . . . . . . . . . . . . . . . . . . . . 6E–37 HO2S Heater . . . . . . . . . . . . . . . . . . . . . . . . . 6E–61
Verifying Vehicle Repair . . . . . . . . . . . . . . . . 6E–37 Catalyst Monitor Heated Oxygen Sensors
General Service Information . . . . . . . . . . . . . . 6E–38 and Diagnostic Operation . . . . . . . . . . . . . . 6E–61
OBD II Serviceablity Issues . . . . . . . . . . . . . 6E–38 Evaporative Emission (EVAP) Purge
Emissions Control Information Label . . . . . 6E–38 System Vacuum Switch . . . . . . . . . . . . . . . . 6E–62
Visual / Physical Engine Compartment Misfire Monitor Diagnostic Operation . . . . . . . 6E–62
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–38 Misfire Monitor Diagnostic Operation . . . . . 6E–62
Basic Knowledge of Tools Required . . . . . . 6E–39 Misfire Counters . . . . . . . . . . . . . . . . . . . . . . . 6E–62
6E–2 TROOPER 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS
Fuel Trim System Monitor Diagnostic Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . 6E–101
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–63 Test Description . . . . . . . . . . . . . . . . . . . . . . . 6E–101
Fuel Trim System Monitor Diagnostic Fuel System Electrical Test . . . . . . . . . . . . . . . 6E–106
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–63 Circuit Description . . . . . . . . . . . . . . . . . . . . . 6E–107
Fuel Trim Cell Diagnostic Weights . . . . . . . 6E–63 Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . 6E–107
On-Board Diagnostic (OBD II) System Test Description . . . . . . . . . . . . . . . . . . . . . . . 6E–107
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–64 Fuel Pressure Relief Procedure . . . . . . . . . 6E–107
Circuit Description . . . . . . . . . . . . . . . . . . . . . 6E–64 Electric Throttle Control (ETC) System
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . 6E–64 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–110
Test Description . . . . . . . . . . . . . . . . . . . . . . . 6E–64 Circuit Description . . . . . . . . . . . . . . . . . . . . . 6E–111
A/C Clutch Control Circuit Diagnosis . . . . . . . 6E–67 Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . 6E–111
Circuit Description . . . . . . . . . . . . . . . . . . . . . 6E–67 Test Description . . . . . . . . . . . . . . . . . . . . . . . 6E–111
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . 6E–67 Fuel System Diagnosis . . . . . . . . . . . . . . . . . . . 6E–114
A/C Clutch Diagnosis . . . . . . . . . . . . . . . . . . 6E–68 Circuit Description . . . . . . . . . . . . . . . . . . . . . 6E–114
Electronic Ignition System Diagnosis . . . . . . . 6E–72 Test Description . . . . . . . . . . . . . . . . . . . . . . . 6E–114
EVAP Canister Purge Solenoid and EVAP Fuel Pressure Relief Procedure . . . . . . . . . 6E–115
Vacuum Switch . . . . . . . . . . . . . . . . . . . . . . . . . 6E–72 Exhaust Gas Recirculation (EGR) System
Visual Check of The Evaporative Emission Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–119
Canister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–72 Circuit Description . . . . . . . . . . . . . . . . . . . . . 6E–119
Fuel Metering System Check . . . . . . . . . . . . . 6E–72 Manifold Absolute Pressure (MAP) Output
Fuel System Pressure Test . . . . . . . . . . . . . . . 6E–72 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–121
Fuel Injector Coil Test Procedure and Fuel Circuit Description . . . . . . . . . . . . . . . . . . . . . 6E–121
Injector Balance Test Procedure . . . . . . . . . . 6E–72 Evaporative (EVAP) Emissions Canister
Test Description . . . . . . . . . . . . . . . . . . . . . . . 6E–72 Purge Valve Check . . . . . . . . . . . . . . . . . . . . . 6E–123
Injector Coil Test Procedure (Steps 1-6) Circuit Description . . . . . . . . . . . . . . . . . . . . . 6E–123
and Injector Balance Test Procedure
(Steps 7-11) . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–73 Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . 6E–123
Powertrain Control Module (PCM) Upshift Lamp System Check (Manual
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–77 Transmission Only) . . . . . . . . . . . . . . . . . . . . . 6E–126
Multiple PCM Information Sensor DTCs Set 6E–77 Circuit Description . . . . . . . . . . . . . . . . . . . . . 6E–127
Circuit Description . . . . . . . . . . . . . . . . . . . . . 6E–77 Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . 6E–127
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . 6E–77 PCM Diagnostic Trouble Codes . . . . . . . . . . . 6E–129
Exhaust Gas Recirculation (EGR) Diagnosis 6E–81 PCM Diagnostic Trouble Codes . . . . . . . . . 6E–129
Engine Tech 2 Data Definitions and Ranges 6E–81 P0101 MAF System Performance . . . . . . . . . 6E–133
Typical Scan Data Values . . . . . . . . . . . . . . . . 6E–83 P0102 MAF Sensor Circuit Low Frequency 6E–136
Test Conditions . . . . . . . . . . . . . . . . . . . . . . . . 6E–83 P0103 MAF Sensor Circuit High Frequency . 6E–139
3.5L V-6 Engine (Automatic and Manual P0106 MAP System Performance . . . . . . . . . 6E–142
Transmission) . . . . . . . . . . . . . . . . . . . . . . . . 6E–84 P0107 MAP Sensor Circuit Low Voltage . . . . 6E–145
No Malfunction Indicator Lamp (MIL) . . . . . . . 6E–89 P0108 MAP Sensor Circuit High Voltage . . . 6E–148
Circuit Description . . . . . . . . . . . . . . . . . . . . . 6E–89 P0112 IAT Sensor Circuit Low Voltage . . . . . 6E–151
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . 6E–89 P0113 IAT Sensor Circuit High Voltage . . . . . 6E–154
Malfunction Indicator Lamp (MIL) “ON” P0117 ECT Sensor Circuit Low Voltage . . . . 6E–157
Steady . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–92 P0118 ECT Sensor Circuit High Voltage . . . . 6E–160
Circuit description . . . . . . . . . . . . . . . . . . . . . 6E–92 P0125 ECT Excessive Time to Closed
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . 6E–92 Loop Fuel Control . . . . . . . . . . . . . . . . . . . . . . . 6E–163
No Reduced Power Lamp (RPL) . . . . . . . . . . 6E–94 P0128 Thermostat Insufficient temperrature
Circuit Description . . . . . . . . . . . . . . . . . . . . . 6E–94 for Stable Opreation . . . . . . . . . . . . . . . . . . . . . 6E–166
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . 6E–94 P0131 HO2S Circuit Low Voltage
Test Description . . . . . . . . . . . . . . . . . . . . . . . 6E–94 Bank 1 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . 6E–169
Reduced Power Lamp (RPL) “ON” Steady . . 6E–97 P0132 HO2S Circuit High Voltage
Circuit Description . . . . . . . . . . . . . . . . . . . . . 6E–97 Bank 1 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . 6E–172
Diagnostic Aids . . . . . . . . . . . . . . . . . . . . . . . . 6E–97 P0133 HO2S Slow Response
Test Description . . . . . . . . . . . . . . . . . . . . . . . 6E–97 Bank 1 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . 6E–175
Engine Cranks But Will Not Run . . . . . . . . . . . 6E–99 P0134 HO2S Circuit Insufficient Activity
Bank 1 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . 6E–179
Circuit Description . . . . . . . . . . . . . . . . . . . . . 6E–101
P0135 HO2S Heater Circuit Bank 1 Sensor 1 6E–182
P0137 HO2S Circuit Low Voltage P0401 EGR Flow Insufficient . . . . . . . . . . . . . 6E–310
Bank 1 Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . 6E–185 P0402 EGR Pintle Crank Error . . . . . . . . . . . . 6E–313
P0138 HO2S Circuit High Voltage P0404 EGR Open Stuck . . . . . . . . . . . . . . . . . 6E–315
Bank 1 Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . 6E–188 P0405 EGR Low Voltage . . . . . . . . . . . . . . . . . 6E–317
P0140 HO2S Circuit Insufficient Activity P0406 EGR High Voltage . . . . . . . . . . . . . . . . 6E–320
Bank 1 Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . 6E–191 P0420 TWC System Low Efficiency Bank 1 . 6E–323
P0141 HO2S Heater Circuit P0430 TWC System Low Efficiency Bank 2 . 6E–326
Bank 1 Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . 6E–194
P0440 EVAP System . . . . . . . . . . . . . . . . . . . . 6E–329
P0151 HO2S Circuit Low Voltage
P0442 EVAP System Small Leak Detected . 6E–332
Bank 2 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . 6E–197
P0446 EVAP Canister Vent Blocked . . . . . . . 6E–335
P0152 HO2S Circuit HIGH Voltage
Bank 2 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . 6E–200 P0452 Fuel Tank Pressure Sensor
(Vapor Pressure Sensor) Low Voltage . . . . . 6E–338
P0153 HO2S Slow Response
Bank 2 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . 6E–203 P0453 Fuel Tank Pressure Sensor
(Vapor Pressure Sensor) High Voltage . . . . . 6E–341
P0154 HO2S Circuit Insufficient Activity
Bank 2 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . 6E–207 P0456 EVAP Very Small Leak . . . . . . . . . . . . 6E–344
P0155 HO2S Heater Circuit P0462 Fuel Level Sensor Circuit–Low
Bank 2 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . 6E–210 Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–347
P0157 HO2S Circuit Low Voltage P0463 Fuel Level Sensor Circuit–High
Bank 2 Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . 6E–213 Voktage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–350
P0158 HO2S Circuit High Voltage P0502 VSS Circuit Low Input . . . . . . . . . . . . . 6E–352
Bank 2 Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . 6E–216 P0506 Idle Air Control System Low RPM . . . 6E–355
P0160 HO2S Circuit Insufficient Activity P0507 Idle Air Control System High RPM . . . 6E–358
Bank 2 Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . 6E–219 P0562 System Voltage Low . . . . . . . . . . . . . . . 6E–361
P0161 HO2S Heater Circuit P0563 System Voltage High . . . . . . . . . . . . . . 6E–363
Bank 2 Sensor 2 . . . . . . . . . . . . . . . . . . . . . . . . 6E–222 P0601 PCM Memory . . . . . . . . . . . . . . . . . . . . 6E–365
P0171 Fuel Trim System Lean Bank 1 . . . . . 6E–225 P0602 PCM Programming Error . . . . . . . . . . . 6E–367
P0172 Fuel Trim System Rich Bank 1 . . . . . . 6E–229 P0604 PCM RAM Error . . . . . . . . . . . . . . . . . . 6E–369
P0174 Fuel Trim System Lean Bank 2 . . . . . 6E–233 P0606 PCM Internal Performance . . . . . . . . . 6E–371
P0175 Fuel Trim System Rich Bank 2 . . . . . . 6E–237 P1106 MAP Sensor Circuit Intermittent
P0201 Injector 1 Control Circuit . . . . . . . . . . . 6E–241 High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–373
P0202 Injector 2 Control Circuit . . . . . . . . . . . 6E–244 P1107 MAP Circuit Intermittent
P0203 Injector 3 Control Circuit . . . . . . . . . . . 6E–247 Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–375
P0204 Injector 4 Control Circuit . . . . . . . . . . . 6E–250 P1111 IAT Sensor Circuit Intermittent
P0205 Injector 5 Control Circuit . . . . . . . . . . . 6E–253 High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–377
P0206 Injector 6 Control Circuit . . . . . . . . . . . 6E–256 P1112 IAT Sensor Circuit Intermittent
Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–380
P0300 Engine Misfire Detected . . . . . . . . . . . 6E–259
P1114 ECT Sensor Circuit Intermittent
P0301 Cylinder Misfire Detected . . . . . . . . . . 6E–263
Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–382
P0302 Cylinder Misfire Detected . . . . . . . . . . 6E–265
P1115 ECT Sensor Circuit Intermittent
P0303 Cylinder Misfire Detected . . . . . . . . . . 6E–267 High Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–384
P0304 Cylinder Misfire Detected . . . . . . . . . . 6E–269 P1120-TPS 1 Throttle Position Sensor
P0305 Cylinder Misfire Detected . . . . . . . . . . 6E–271 (TPS1) Circuit Fault . . . . . . . . . . . . . . . . . . . . . 6E–387
P0306 Cylinder Misfire Detected . . . . . . . . . . 6E–273 P1125 ETC (Electric Throttle Control)
P0325 ION Sensing Module/ION Sensing Limit Performance Mode . . . . . . . . . . . . . . . . . 6E–390
Knock Intensity Circuit Fault . . . . . . . . . . . . . . 6E–275 P1133 HO2S Insufficient Switching
P0336 58X Reference Signal Circuit . . . . . . . 6E–278 Bank 1 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . 6E–393
P0337 CKP Sensor Circuit Low Frequency . 6E–281 P1134 HO2S Transition Time Ratio
P0341 CMP Sensor Circuit Performance . . . 6E–284 Bank 1 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . 6E–397
P0342 CMP Sensor Circuit Low . . . . . . . . . . . 6E–288 P1153 HO2S Insufficient Switching
P0351 Ignition 1 Control Circuit . . . . . . . . . . . 6E–292 Bank 2 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . 6E–401
P0352 Ignition 2 Control Circuit . . . . . . . . . . . 6E–295 P1154 HO2S Circuit Transition Time Ratio
P0353 Ignition 3 Control Circuit . . . . . . . . . . . 6E–298 Bank 2 Sensor 1 . . . . . . . . . . . . . . . . . . . . . . . . 6E–405
P0354 Ignition 4 Control Circuit . . . . . . . . . . . 6E–301 P1167 Fuel System Rich During Decel Fuel
P0355 Ignition 5 Control Circuit . . . . . . . . . . . 6E–304 Cut Off (Bank 1) . . . . . . . . . . . . . . . . . . . . . . . . 6E–409
P0356 Ignition 6 Control Circuit . . . . . . . . . . . 6E–307
P1169 Fuel System Rich During Decel Fuel Service Precaution . . . . . . . . . . . . . . . . . . . . 6E–534
Cut Off (Bank 2) . . . . . . . . . . . . . . . . . . . . . . . . 6E–411 Removal Procedure . . . . . . . . . . . . . . . . . . . . 6E–534
P1171 Fuel System Lean During Installation Procedure . . . . . . . . . . . . . . . . . . 6E–535
Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–413 EEPROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–535
P1220 Throttle Position Senser2 (TPS2) Throttle Position (TP) Sensor . . . . . . . . . . . . . 6E–536
Circuit Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–416 Vehicle Speed Sensor (VSS) . . . . . . . . . . . . . 6E–536
P1221 TPS1 – TPS2 correlation Air Cleaner/Air Filter . . . . . . . . . . . . . . . . . . . . . 6E–538
(Circuit Performance) . . . . . . . . . . . . . . . . . . . . 6E–419
Common Chamber . . . . . . . . . . . . . . . . . . . . . . 6E–538
P1271 APS 1– 2 Correlation Error . . . . . . . . 6E–422
Accelerator Pedal Replacement . . . . . . . . . . . 6E–539
P1272 APS 2 – 3 Correlation Error . . . . . . . . 6E–425
Fuel Filler Cap . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–540
P1273 APS 1 – 3 Correlation Error . . . . . . . . 6E–428
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–540
P1275 APS 1 Circuit Fault . . . . . . . . . . . . . . . . 6E–431
Fuel Gauge Unit . . . . . . . . . . . . . . . . . . . . . . . . 6E–542
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–543
Fuel Metering System . . . . . . . . . . . . . . . . . . . . 6E–544
P1290 ETC Forced Idle Mode . . . . . . . . . . . . . 6E–437
Fuel Pump Assembly . . . . . . . . . . . . . . . . . . . . 6E–545
P1295 Power Management Mode . . . . . . . . . 6E–440
Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . . . 6E–545
P1299 ETC Forced Engine Shutdown Mode 6E–444
Fuel Rail Assembly . . . . . . . . . . . . . . . . . . . . . . 6E–546
P1310 ION Sensing Module Diagnosis . . . . 6E–448
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–547
P1311 ION Sensing Module SEC line 1
Throttle Body (TB) . . . . . . . . . . . . . . . . . . . . . . . 6E–549
Circuit Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–452
Electronic Ignition System . . . . . . . . . . . . . . . . 6E–551
P1312 ION Sensing Module SEC line 2
Circuit Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–455 Catalytic Converter . . . . . . . . . . . . . . . . . . . . . . 6E–552
P1326 ION Sensing Module Combustion Air Conditioning Thermo Relay . . . . . . . . . . . 6E–552
Quality Input Circuit Fault . . . . . . . . . . . . . . . . 6E–458 EVAP Canister Hoses . . . . . . . . . . . . . . . . . . . . 6E–552
P1340 ION Sensing Module Cylinder ID Fault EVAP Canister . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–553
(Cylinder Synchronization Fail) . . . . . . . . . . . . 6E–461 EVAP Canister Vent Solenoid . . . . . . . . . . . . . 6E–554
P1404 EGR Stuck Closed . . . . . . . . . . . . . . . . 6E–464 Fuel Tank Pressure Sensor . . . . . . . . . . . . . . . 6E–555
P1441 EVAP System Flow During EVAP Canister Purge Solenoid . . . . . . . . . . . . 6E–555
Non-Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–467 Fuel Tank Vent Valve . . . . . . . . . . . . . . . . . . . . 6E–556
P1514 TPS - MAF Correlation Error . . . . . . . 6E–470 Linear Exhaust Gas Recirculation
P1515 Command - Actual TPS Correlation (EGR) Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–556
Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–474 Positive Crankcase Ventilation (PCV) Valve . 6E–557
P1516 Command - Actual TPS Correlation PCV Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–557
Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–477 Wiring and Connectors . . . . . . . . . . . . . . . . . . . 6E–558
P1523 Actuator Control Return Performance 6E–480 PCM Connectors and Terminals . . . . . . . . . . . 6E–558
P1625 PCM Unexpected Reset . . . . . . . . . . . 6E–483 Wire Harness Repair: Twisted Shielded
P1635 Reference Voltage # 1 Circuit Fault . . 6E–484 Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–558
P1639 Reference Voltage # 2 Circuit Fault . . 6E–486 Twisted Leads . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–559
P1640 Driver-1-Output Circuit Fault (ODM) . 6E–488 Weather-Pack Connector . . . . . . . . . . . . . . . . . 6E–561
P1650 Quad Driver Module “A” Fault . . . . . . 6E–491 Com-Pack III . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–562
Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . 6E–494 Metri-Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–562
Default Matrix Table . . . . . . . . . . . . . . . . . . . . . 6E–523 General Description (PCM and Sensors) . . . 6E–563
Default Matrix Table . . . . . . . . . . . . . . . . . . . . 6E–523 58X Reference PCM Input . . . . . . . . . . . . . . 6E–563
On-Vehicle ServiceCamshaft Position A/C Request Signal . . . . . . . . . . . . . . . . . . . . 6E–563
(CMP) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–526 Crankshaft Position (CKP) Sensor . . . . . . . 6E–563
Crankshaft Position (CKP) Sensor . . . . . . . . . 6E–527 Camshaft Position (CMP) Sensor
Engine Coolant Temperature (ECT) Sensor . 6E–527 and Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–563
Heated Oxygen Sensor (HO2S) . . . . . . . . . . . 6E–528 Engine Coolant Temperature (ECT) Sensor 6E–563
Intake Air Temperature (IAT) Sensor . . . . . . . 6E–531 Electrically Erasable Programmable Read
ION Sensing Module . . . . . . . . . . . . . . . . . . . . . 6E–531 Only Memory (EEPROM) . . . . . . . . . . . . . . 6E–564
Mass Air Flow (MAF) Sensor . . . . . . . . . . . . . 6E–532 Fuel Control Heated Oxygen Sensors . . . . 6E–564
Manifold Absolute Pressure (MAP) Sensor . 6E–533 Catalyst Monitor Heated Oxygen Sensors 6E–564
Malfunction Indicator Lamp (MIL) . . . . . . . . . . 6E–534 Intake Air Temperature (IAT) Sensor . . . . . 6E–565
Reduced Power Lamp . . . . . . . . . . . . . . . . . . . 6E–534 Linear Exhaust Gas Recirculation
Powertrain Control Module (PCM) . . . . . . . . . 6E–534 (EGR) Control . . . . . . . . . . . . . . . . . . . . . . . . 6E–565
Mass Air Flow (MAF) Sensor . . . . . . . . . . . . 6E–565 Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–571
Manifold Absolute Pressure (MAP) Sensor 6E–565 Starting Mode . . . . . . . . . . . . . . . . . . . . . . . . . 6E–571
Powertrain Control Module (PCM) . . . . . . . 6E–566 Throttle Body Unit . . . . . . . . . . . . . . . . . . . . . 6E–571
PCM Function . . . . . . . . . . . . . . . . . . . . . . . . . 6E–566 General Description
PCM Components . . . . . . . . . . . . . . . . . . . . . 6E–566 (Electronic Ignition System) . . . . . . . . . . . . . . 6E–571
PCM Voltage Description . . . . . . . . . . . . . . . 6E–566 Camshaft Position (CMP) Sensor . . . . . . . . 6E–571
PCM Input/Outputs . . . . . . . . . . . . . . . . . . . . 6E–567 Crankshaft Position (CKP) Sensor . . . . . . . 6E–571
PCM Service Precautions . . . . . . . . . . . . . . 6E–567 Electronic Ignition . . . . . . . . . . . . . . . . . . . . . 6E–572
Reprogramming The PCM . . . . . . . . . . . . . . 6E–567 Ignition Coils . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–572
Throttle Position (TP) Sensor . . . . . . . . . . . 6E–567 Ignition Control . . . . . . . . . . . . . . . . . . . . . . . . 6E–572
Transmission Fluid Temperature Ignition Control PCM Output . . . . . . . . . . . . 6E–573
(TFT) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . 6E–567 Powertrain Control Module (PCM) . . . . . . . 6E–573
Transmission Range Switch . . . . . . . . . . . . . 6E–567 Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–574
Vehicle Speed Sensor (VSS) . . . . . . . . . . . . 6E–568 A/C Clutch Diagnosis . . . . . . . . . . . . . . . . . . . . 6E–575
Use of Circuit Testing Tools . . . . . . . . . . . . . 6E–568 A/C Clutch Circuit Operation . . . . . . . . . . . . 6E–575
Aftermarket Electrical and Vacuum A/C Clutch Circuit Purpose . . . . . . . . . . . . . 6E–575
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–568 A/C Request Signal . . . . . . . . . . . . . . . . . . . . 6E–575
Electrostatic Discharge Damage . . . . . . . . . 6E–568 General Description (Evaporative (EVAP)
Upshift Lamp . . . . . . . . . . . . . . . . . . . . . . . . . 6E–568 Emission System) . . . . . . . . . . . . . . . . . . . . . . 6E–576
General Description (Air Induction) . . . . . . . . 6E–568 EVAP Emission Control System Purpose . 6E–576
Air Induction System . . . . . . . . . . . . . . . . . . . 6E–568 EVAP Emission Control System Operation 6E–576
General Description (Fuel Metering) . . . . . . . 6E–569 Enhanced Evaporative Emission Control
Acceleration Mode . . . . . . . . . . . . . . . . . . . . . 6E–569 System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–576
General Description (Exhaust Gas
Battery Voltage Correction Mode . . . . . . . . 6E–569
Recirculation (EGR) System) . . . . . . . . . . . . . 6E–579
CMP Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–569
EGR Purpose . . . . . . . . . . . . . . . . . . . . . . . . . 6E–579
Clear Flood Mode . . . . . . . . . . . . . . . . . . . . . 6E–569
Linear EGR Valve . . . . . . . . . . . . . . . . . . . . . 6E–580
Deceleration Mode . . . . . . . . . . . . . . . . . . . . 6E–569
Linear EGR Control . . . . . . . . . . . . . . . . . . . . 6E–580
Engine Speed/Vehicle Speed/Fuel
Linear EGR Valve Operation and Results
Disable Mode . . . . . . . . . . . . . . . . . . . . . . . . 6E–569
of Incorrect Operation . . . . . . . . . . . . . . . . . 6E–580
Fuel Cutoff Mode . . . . . . . . . . . . . . . . . . . . . . 6E–569
EGR Pintle Position Sensor . . . . . . . . . . . . . 6E–580
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–569
General Description (Positive Crankcase
Fuel Metering System Components . . . . . . 6E–569
Ventilation (PCV) System) . . . . . . . . . . . . . . . 6E–580
Fuel Metering System Purpose . . . . . . . . . . 6E–570
Crankcase Ventilation System Purpose . . . 6E–580
Fuel Pressure Regulator . . . . . . . . . . . . . . . . 6E–570
Crankcase Ventilation System Operation . 6E–580
Fuel Pump Electrical Circuit . . . . . . . . . . . . . 6E–570
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–582
Fuel Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E–570
Specifications
Tightening Specifications
Application N·m Lb Ft. Lb In.
Camshaft Position Sensor Retaining Screw 9 — 78
Crankshaft Position Sensor Mounting Bolt 9 — 78
EGR Bolt 25 18 —
Engine Coolant Temperature Sensor 30 22 —
Fuel Drain Plug 20 14 —
Fuel Pressure Regulator Attaching Screw 3 — 26
Fuel Rail Bolts 25 18 —
Fuel Tank Undercover Retaining Bolts 36 27 —
Heated Oxygen Sensor 55 40 —
Lower Intake Manifold to Engine Block Bolts 25 18 —
Lower Intake Manifold to Engine Block Nuts 25 18 —
Spark Plugs 18 13 —
Throttle Body Mounting Bolts 10 — 87
Common Chamber to Lower Intake Manifold Bolts 25 18 —
VSS Retaining Bolt 16 12 —
Diagrams and Schematics

PCM Wiring Diagram (1 of 7)
D06RY00156
D06RY00150
D06RY00042
D06RY00044
D06RY00149
D06RY00115
D06RY00127
PCM Pinouts
PCM Pinout Table, 80-Way Blue Connector – Row “F1 ∼ 20”
060RY00045
PIN PIN Function Wire Color IGN ON ENG RUN Refer To

F1 PCM Ground BLK/BLU 0.0V 0.0V Chassis Electrical
F2 5Volt Referrence“2” (AP GRN 5.0V 5.0V AP Sensor
Sensor 2)
F3 5Volt Referrence“2” (TP RED/WHT 5.0V 5.0V AP Sensor
Sensor 2)
F4 A/C Clutch GRN/BLK B+(A/C off) B+(A/C off) General Description and
Operation,A/C Cluch Circuit
Opreation
F5 Mission Main Case GRN/RED 0.0V 0.0V 4L30E T/Mission
F6 Not Used — — — —
F7 Tachometer BLK/RED 8.8V 10.0V(at idle) Chassis Electrical
F12 Camshaft Position Sensor WHT/RED 5.0V or less 4.6V General Description and
than 1.0V Operation,Camshaft Position
Sensor
F14 Mass Air Flow(MAF) BLK/BLU 4.9V 4.2V General Description, Mass
Air Flow Sensor
F17 Bank 1 HO2S Low RED 0.0V 0.1V General Description and
Operation, Catalyst Monitor
HO2S 2

F19 Ignition Feed RED/GRN B+ B+ 6D Section
F20 Ignition Feed RED/WHT B+ B+ 6D Section
060RY00156

F21 Bank 1 HO2S 1 Ground WHT 0.0V 0.0V General Description and
HO2S 1
F23 Bank 2 HO2S 1 Ground BLU 0.0V 0.0V General Description and
HO2S 1
F25 ION Sensing Module RED/BLU 1.555V 1.555V General Description and
Operation,ION Sensing
Module
F26 ION Sensing Module RED/BLK 1.555V 1.555V General Description and
Operation,ION Sensing
Module
F27 Intake Air Temperature YEL/GRN 0.5–4.9V 0.5–4.9V General Description and
(IAT)Sensor Operation, IAT
F29 Manifold Absolute RED 3.5V–4.9V 0.6-1.3V General Description and
Pressure(MAP) (depends on Operation, Manifold Absolute
altitude and Pressure
barometric
pressure)
F31 Low Fuel Lamp YEL/BRN B+ B+ Chassis Electrical
F32 Power Lamp GRN/WHT B+ B+ 4L30E T/Mission
F33 Reduse Power Lamp RED/WHT B+ B+ Chassis Electrical
F37 Power Steering Pressure GRN/YEL B+ B+ Power Steering
(PSP)
F38 Illuminated Switch GRN/YEL B+ B+ Chassis Electrical

F39 Brake Swich GRN/YEL 0.0V 0.0V 4L30E T/Mission
F40 PCM Ground BLK/RED 0.0V 0.0V Chassis Electrical
060RY00046

F41 Throttle Position(TP) 1 GRN 0.0V 0.0V General Description and
Sensor Ground Operation,TPS
F42 Fuel Pump Relay SIL/BLK 0.0V B+ On Vehicle Service, Fuel
Pump Relay
F43 Adaptor Case RED/WHT 0.0V 0.0V 4L30E T/Mission
F44 Bank 1 HO2S 2 Heater BLK/PNK 0.0V 0.0V General Description and
Ground Operation, Catalyst Monitor
HO2S 2
F45 A/C Request GRN/ORN 0.0V 0.0V Chassis Electrical
F46 Auto Cruise Brake Switch ORN 0.0V 0.0V Chassis Electrical
F47 Adaptor Case VIO/RED B+ B+ 4L30E T/Mission
F48 Throttle Valve DC BLK Duty Cycle Duty Cycle General Description and
Motor(–) Operation, ETC
F49 Shielded Wire (ION SIL 0.0V 0.0V Chassis Electrical
Sensing Module)
F50 Bank 2 HO2S 2 Ground ORN 0.0V 0.0V General Description and
HO2S 2
F51 DLC Serial Data ORN 5.0V 5.0V Chassis Electrical
F52 Bank 1 HO2S 2 Ground RED 0.0V 0.0V General Description and
HO2S 2
F53 ECT Ground GRN 0.0V 0.0V General Description and
Operation,ECT Sensor
F54 Vapor Pressure Sensor GRY/RED 0.0V 0.0V General Description and
Ground Operation,VP Sensor
F56 Injector Cylinder #5 GRN/BLK B+ B+ General Description and
Operation,Fuel Injector
F57 Ignition Feed WHT B+ B+ Chassis Electrical
F58 Class 2 Data ORN/GRN 0.0V 0.0V General Description

F60 Shielded Wire SIL 0.0V 0.0V Chassis Electrical
060RY00047

F61 Throttle Position(TP) 2 GRN/WHT 0.0V 0.0V General Description and
Sensor Ground Operation,TPS
F62 Injector Cylinder #2 GRN/ORN B+ B+ General Description and
F63 AP Sensor 1 Sensor RED 0.0V 0.0V General Description and
Ground Operation,APS
F64 Injector Cylinder #4 GRN/RED B+ B+ General Description and
F65 Throttle Psition(TP) 2 BLU/WHT 0.5–0.8V 0.8–0.8V (at General Description and
Sensor Signal idle) Operation,TPS
F66 Injector Cylinder #3 GRN B+ B+ General Description and
F67 ION Sensing Module YEL 1.555V 1.555V General Description and
Operation, ION Sensing
Module
F68 ION Sensing Module RED 1.555V 1.555V General Description and
Module
F69 Injector Cylinder #1 GRN/WHT B+ B+ General Description and
F71 Bank 2 HO2S 2 Heater BLK 0.0V 0.0V General Description and
HO2S 2
F72 Auto Cruise Switch BRN/YEL 0.0V 0.0V Chassis Electrical
Resume
F73 Cranshaft Position Sensor YEL 0.3V 2.2V General Description and
Operation, CKP sensor
F74 ECT Sensor BLU/RED 0.5–4.9V 0.5–4.9V General Description and
Operation, ECT Sensor
F75 Ignition Feed RED/BLU B+ B+ Chassis Electrical
F76 Clutch Switch(M/T only) YEL/GRN B+ B+ Manual T/Mission
Mode Switch(A/T only) YEL/GRN B+ B+ 4L30E T/Mission

F77 Mode Switch BLU/WHT B+ B+ 4L30E T/Mission
F78 Mode Switch BLU/BLK B+ B+ 4L30E T/Mission
F79 Mode Switch BLU/YEL B+ B+ 4L30E T/Mission
F80 AP Sensor 2 Sensor BLU 0.0V 0.0V General Description and
Ground Operation, APS
PCM Pinout Table, 80-Way Red Connector – Row “S1 ∼ 20”
060RY00069

S1 PCM Ground BLK/WHT 0.0V 0.0V Chassis Electrical
S2 Bank 1 HO2S 1 Heater BLK 0.0V 0.0V General Description and
HO2S
S3 Not Used — — — —
S4 ATF Warning Lamp ORN/BLU B+ B+ 4L30E T/Mission
S5 5Volt Referrence“2” (CKP YEL/RED 5.0V 5.0V Appropriate Sensor (CKP
Sensor/CMP Sensor) Sensor, CMP Sensor ,AP2
Sensor)
S6 Auto Cruise Switch Cancel GRY/GRN 0.0V 0.0V Chassis Electrical
S7 Fuel Gauge YEL/RED B+ B+ Chassis Electrical
S10 Shift High(Band Apply) BRN/YEL B+ B+ 4L30E T/Mission
S11 Malfunction Indicator VIO 0.0V B+ Chassis Electrical
(Check Engine) Lamp
S13 ION Sensing Module RED/WHT 1.555V 1.555V General Description and
Module
S14 Bank 2 HO2S 1 Ground BLU 0.0V 0.0V General Description and
Jump Operation, Catalyst Monitor
HO2S 1
S15 Bank 2 HO2S 2 Ground ORN 0.0V 0.0V General Description and
HO2S 2
S16 Bank 2 HO2S 2 Low BLU 0.0V 0.1V General Description and
HO2S
S17 Bank 1 HO2S 1 Ground WHT 0.0V 0.0V General Description and
HO2S 1

S18 Bank 1 HO2S 1 Low GRN 0.0V 0.1V General Description and
HO2S
S19 ION Sensing Module RED/YEL 1.555V 1.555V General Description and
Module
S20 Transmission Fluid 0.0V 0.0V 4L30E T/Mission
Temperature Sensor
Ground
060RY00049

S22 Transmissin Output Speed RED 0.0V 0.0V 4L30E T/Mission
Sensor
S23 PCM Ground BLK/RED 0.0V 0.0V Chassis Electrical
S24 Bank 1 HO2S 2 Ground RED 0.0V 0.0V General Description and
HO2S 2
S26 EGR Control Low BLK/YEL B+ B+ General Description and
Operation, EGR Control
S27 VSS Input Light 0.0V 0.1V (at rest) Chassis Electrical
GRN/WHT
S28 Injector Cylinder #6 GRN/YEL B+ B+ General Description and
Operation, Fuel Injector
S29 Winter Switch VIO/GRN B+ B+ 4L30E T/Mission
S30 Auto Cruise Main Switch PNK/BLK 0.0V 0.0V Chassis Electrical
S31 Transmissin Range GRN 0.0V 0.0V 4L30E T/Mission
Signal“2–3’’
S32 Ignition Feed RED/BLU B+ B+ Chassis Electrical
S33 TCC Solenoid RED/BRN 0.0V 0.0V T/Mission
S35 ION Sensing Module RED/GRN 1.555V 1.555V General Description and
Module
S36 5Volt Referrence (AP BLK 5.0V 5.0V AP Sensor
Sensor 1)
S37 5Volt Referrence (Fuel RED/YEL 5.0V 5.0V (Fuel Tank Pressure
Tank Pressure Sensor/MAP Sensor/EGR
Sensor/MAP Sensor/EGR Posistion Sensor) Sensor
Posistion Sensor)
S38 5Volt Referrence (TP RED/YEL 5.0V 5.0V TP Sensor
Sensor 1)

S39 Auto Cruise Lamp BLK/ORN 0.0V 0.0V Chassis Electrical
S40 PCM Ground BLK 0.0V 0.0V Chassis Electrical
060RY00050

S41 AP Sensor 3 Sensor BLU/ORN 0.0V 0.0V General Description and
Ground Operation, APS
S42 Bank 2 HO2S 1 Heater BLK 0.0V 0.0V General Description and
HO2S
S43 Transmissin Range GRY/WHT 0.0V 0.0V 4L30E T/Mission
Signal“1–2’’ “3–4’’
S45 Antilock Brake System VIO/WHT B+ B+ Antilock Brake System
(ABS) Off Switch
S46 A/T Check Transmission ORN/BLK B+ B+ Chassis Electrical
Lamp
M/T Up Shift Lamp ORN/BLK B+ B+ Chassis Electrical
S47 Winter Lamp PNK/GRN B+ B+ 4L30E T/Mission
S48 EVAP Duty Solenoid Valve RED/BLU B+ 5.7V General Description and
Operation, EVAP Emission
Control System
S49 DLC ORN/BLU B+ B+ General Description
S50 Fuel Sender Unit YEL/VIO 0.0V 0.0V —
S51 TCC Solenoid BRN/BLU B+ B+ T/Mission
S52 Vapor Pressure Sensor GRY 0.2–4.8V 0.2–4.8V General Description and
Signal Operation,VP Sensor
S53 Power Switch VIO/RED B+ B+ 4L30E T/Mission
S54 Bank 2 HO2S 1 Low BLU 0.0V 0.1V General Description and
HO2S
S55 Transmissin Output Speed WHT 0.0V 0.0V 4L30E T/Mission
Sensor

S58 Bank 2 HO2S 1 High RED 0.3V 0.1–0.9V General Description and
HO2S
S59 Auto Cruise Steering Set Light GRN 0.0V 0.0V Chassis Electrical
Switch
S60 Fuel Sender Unit GRY 0.5–4.9V 0.5–4.9V ON-Vehicle Service PCM
and Sensors
060RY00051

S61 Intake Air Temperature GRN 0.0V 0.0V General Description and
(IAT)Sensor Ground Operation, IAT
S62 ION Sensing Module RED 1.555V 1.555V General Description and
Module
S63 Bank 1 HO2S 2 High WHT 0.3V 0.1–0.9V General Description and
HO2S
S64 Bank 2 HO2S 1 High PNK 0.3V 0.1–0.9V General Description and
HO2S
S65 Bank 2 HO2S 2 High GRN 0.3V 0.1–0.9V General Description and
HO2S
S66 Transmission Fluid RED/WHT 0.5–4.9V 0.5–4.9V 4L30E T/Mission
Temperature Sensor (depends on (depends on
temperature) temperature)
S67 Exhaust Gas Recirculation YEL/RED 0.6V 0.6V General Description and
(EGR) Operation,EGR Control
S68 Accelerator Position(AP) WHT 0.41–0.45V 0.41–0.45V General Description and
Sensor 1 Operation,AP Sensor
S69 Throttle Valve DC BLK Duty Cycle Duty Cycle General Description and
Motor(+) Operation,ETC
S72 Ignition Feed for ETC RED/BLU B+ B+ Chassis Electrical
S73 Auto Cruise Main Lamp GRY/BLU B+ B+ Chassis Electrical
S74 Variable Intake Manifold WHT/BLU 0.0V B+(rpm 3600 General Description
over)
S75 Canister Vent Valve BLU/PNK 6.0V Tank 5.7V Tank General Description and
empty empty Operation, EVAP
S76 Throttle Position(TP) 1 BLU/PNK 0.5–0.8V 0.5–0.8V (at General Description and
Sensor Signal idle) Operation,TPS

S77 5Volt Referrence (AP ORN 5.0V 5.0V Appropriate Sensor
Sensor 3)
S78 Accelerate Position(AP) YEL 0.41–0.45V 0.41–0.45V General Description and
S79 Accelerate Position(AP) BLU/GRN 4.55–4.99V 0.41–0.45V General Description and
S80 Manifold Absolute BLU 0V 0V General Description and
Pressure(MAP) Operation, Manifold Absolute
Pressure
Component Locators
Engine Component Locator
060RY00070
Engine Component Locator Table
Number Name Location

1 Linear Exhaust Gas Recirculation (EGR) Valve Rear right side of the engine
2 Throttle Position (TP) Sensor On the throttle body
3 Intake Air Temperature (IAT) Sensor On the intake air duct near the throttle body
4 Check Engine (MIL) Light On the instrument panel beneath the
tachometer
5 Positive Crankcase Ventilation (PCV) Valve On the left of the cylinder head cover
6 Air Cleaner Left front of the engine bay
7 Mass Air Flow (MAF) Sensor Attached to the air filter box
8 Camshaft Position (CMP) Sensor On the rear right side of the left cylinder head
9 Fuel Pressure Regulator Rear side of the engine
10 ION Sensing module Bolted to the top of the Common Chamber
11 Common Chamber Top of the engine
12 EVAP Canister Purge Valve Bolted to the front of the coolant pipe
13 Fuse/Relay Box Along the inside of the right fender
14 Manifold Absolute Pressure (MAP) Sensor Bolted to the top of the Common Chamber
15 Throttle Body Between the intake air duct and the Common
Chamber
16 Engine Coolant Temperature Sensor On the coolant crossover pipe at the front of
the engine, near the throttle body
17 Power Train Control Module (PCM) Along the inside of the right fender
Undercarriage Component Locator
F00RW032
Undercarriage Component Locator Table
Number Name Location

1 Fuel Pump Assembly Installed in the top of the fuel tank
2 EVAP Canister On the top of the bracket that is located behind
of the cross member
3 EVAP Canister Cut Valve On the top of the bracket that is located behind
of the cross member
4 Fuel Gauge Unit Installed in the front edge of the fuel tank, on
the right side
5 Fuel Filter Located along the inside of the right frame rail,
ahead of the rear axle
6 Vehicle Speed Sensor (VSS) 2WD: Protrudes from the transmission
housing, just ahead of the propeller shaft.
4WD: Protrudes from the rear output shaft
housing of the transfer case.
7 Heated Oxygen Sensor (Bank 1, HO2S 1) Threaded into the exhaust pipe behind the
right-hand catalytic converter
8 Heated Oxygen Sensor (Bank 1, HO2S 2) Threaded into the exhaust pipe ahead of the
right-hand catalytic converter
9 Heated Oxygen Sensor (Bank 2, HO2S 1) Threaded into the exhaust pipe ahead the
left-hand catalytic converter
10 Heated Oxygen Sensor (Bank 2, HO2S 2) Threaded into the exhaust pipe behind the
left-hand catalytic converter
Fuse and Relay Panel (Underhood Electrical Center)
065RY00003
Sensors and Miscellaneous Component Locators
060RY00013 060RX00005
T321067 060RW111
T321068 141RY00001
055RY00002 T321078
041RW004 060RY00014
025RW005 060RY00016
060RY00023
Diagnosis 3. Use a check sheet or other method to identify the

circuit or electrical system component.
Strategy-Based Diagnostics 4. Follow the suggestions for intermittent diagnosis
found in the service documentation.
Strategy-Based Diagnostics Most Scan Tools, such as the Tech 2, have data-capturing
The strategy-based diagnostic is a uniform approach to capabilities that can assist in detecting intermittents.
repair all Electrical/Electronic (E/E) systems. The
diagnostic flow can always be used to resolve an E/E No Trouble Found
system problem and is a starting point when repairs are This condition exists when the vehicle is found to operate
necessary. The following steps will instruct the technician normally. The condition described by the customer may
how to proceed with a diagnosis: be normal. Verify the customer complaint against another
1. Verify the customer complaint. vehicle that is operating normally. The condition may be
intermittent. Verify the complaint under the conditions
D To verify the customer complaint, the technician described by the customer before releasing the vehicle.
should know the normal operation of the system.
1. Re-examine the complaint.
2. Perform preliminary checks.
When the Complaint cannot be successfully found or
D Conduct a thorough visual inspection. isolated, a re-evaluation is necessary. The complaint
D Review the service history. should be re-verified and could be intermittent as
defined in Intermittents section, or could be normal.
D Detect unusual sounds or odors.
2. Repair and verify.
D Gather diagnostic trouble code information to After isolating the cause, the repairs should be made.
achieve an effective repair. Validate for proper operation and verify that the
3. Check bulletins and other service information. symptom has been corrected. This may involve road
D This includes videos, newsletters, etc. testing or other methods to verify that the complaint
has been resolved under the following conditions:
4. Refer to service information (manual) system
check(s). D Conditions noted by the customer.
D “System checks” contain information on a system D If a DTC was diagnosed, verify a repair by
that may not be supported by one or more DTCs. duplicating conditions present when the DTC was
System checks verify proper operation of the set as noted in the Failure Records or Freeze
system. This will lead the technician in an Frame data.
organized approach to diagnostics.
5. Refer to service diagnostics. Verifying Vehicle Repair
Verification of the vehicle repair will be more
DTC Stored comprehensive for vehicles with OBD II system
Follow the designated DTC chart exactly to make an diagnostics. Following a repair, the technician should
effective repair. perform the following steps:
IMPORTANT: Follow the steps below when you verify
No DTC repairs on OBD II systems. Failure to follow these steps
Select the symptom from the symptom tables. Follow the could result in unnecessary repairs.
diagnostic paths or suggestions to complete the repair.
1. Review and record the Failure Records and the
You may refer to the applicable component/system check
Freeze Frame data for the DTC which has been
in the system checks. diagnosed (Freeze Frame data will only be stored for
an A or B type diagnostic and only if the MIL(”Check
No Matching Symptom Engine” lamp) has been requested).
1. Analyze the complaint. 2. Clear the DTC(S).
2. Develop a plan for diagnostics. 3. Operate the vehicle within conditions noted in the
3. Utilize the wiring diagrams and the theory of Failure Records and Freeze Frame data.
operation. 4. Monitor the DTC status information for the DTC which
Combine technician knowledge with efficient use of the has been diagnosed until the diagnostic test
available service information. associated with that DTC runs.
Intermittents
Conditions that are not always present are called
intermittents. To resolve intermittents, perform the
following steps:
1. Observe history DTCs, DTC modes, and freeze
frame data.
2. Evaluate the symptoms and the conditions described
by the customer.
General Service Information Refueling

A new OBD II diagnostic was introduced in 1996 on some
OBD II Serviceablity Issues vehicles. This diagnostic checks the integrity of the entire
evaporative emission system. If the vehicle is restarted
With the introduction of OBD II diagnostics across the
after refueling and the fuel cap is not secured correctly,
entire passenger car and light-duty truck market in 1996,
the on-board diagnostic system will sense this as a
illumination of the MIL (“Check Engine” lamp) due to a
system fault and turn on the MIL (“Check Engine” lamp)
non-vehicle fault could lead to misdiagnosis of the
with a DTC P0440.
vehicle, increased warranty expense and customer
dissatisfaction. The following list of non-vehicle faults Vehicle Marshaling
does not include every possible fault and may not apply The transportation of new vehicles from the assembly
equally to all product lines. plant to the dealership can involve as many as 60 key
Fuel Quality cycles within 2 to 3 miles of driving. This type of operation
contributes to the fuel fouling of the spark plugs and will
Fuel quality is not a new issue for the automotive industry,
turn on the MIL (“Check Engine” lamp) with a P0300
but its potential for turning on the MIL (“Check Engine”
Misfire DTC.
lamp) with OBD II systems is new.
Fuel additives such as “dry gas” and “octane enhancers” Poor Vehicle Maintenance
may affect the performance of the fuel. If this results in an The sensitivity of OBD II diagnostics will cause the MIL
incomplete combustion or a partial burn, it will show up as (“Check Engine” lamp) to turn on if the vehicle is not
a Misfire DTC P0300. The Reid Vapor Pressure of the maintained properly. Restricted air filters, fuel filters, and
fuel can also create problems in the fuel system, crankcase deposits due to lack of oil changes or improper
especially during the spring and fall months when severe oil viscosity can trigger actual vehicle faults that were not
ambient temperature swings occur. A high Reid Vapor previously monitored prior to OBD II. Poor vehicle
Pressure could show up as a Fuel Trim DTC due to maintenance can’t be classified as a “non-vehicle fault”,
excessive canister loading. High vapor pressures but with the sensitivity of OBD II diagnostics, vehicle
generated in the fuel tank can also affect the Evaporative maintenance schedules must be more closely followed.
Emission diagnostic as well. Related System Faults
Using fuel with the wrong octane rating for the vehicle Many of the OBD II system diagnostics will not run if the
may cause driveability problems. Many of the major fuel PCM detects a fault on a related system or component.
companies advertise that using “premium” gasoline will One example would be that if the PCM detected a Misfire
improve the performance of the vehicle. Most premium fault, the diagnostics on the catalytic converter would be
fuels use alcohol to increase the octane rating of the fuel. suspended until Misfire fault was repaired. If the Misfire
Although alcohol-enhanced fuels may raise the octane fault was severe enough, the catalytic converter could be
rating, the fuel’s ability to turn into vapor in cold damaged due to overheating and would never set a
temperatures deteriorates. This may affect the starting Catalyst DTC until the Misfire fault was repaired and the
ability and cold driveability of the engine. Catalyst diagnostic was allowed to run to completion. If
Low fuel levels can lead to fuel starvation, lean engine this happens, the customer may have to make two trips to
operation, and eventually engine misfire. the dealership in order to repair the vehicle.
Non-OEM Parts
All of the OBD II diagnostics have been calibrated to run Emissions Control Information Label
with OEM parts. Something as simple as a The engine compartment “Vehicle Emissions Control
high-performance exhaust system that affects exhaust Information Label” contains important emission
system back pressure could potentially interfere with the specifications and setting procedures. In the upper left
operation of the EGR valve and thereby turn on the MIL corner is exhaust emission information. This identifies
(“Check Engine” lamp). Small leaks in the exhaust the emission standard (Federal, California, or Canada) of
system near the post catalyst oxygen sensor can also the engine, the displacement of the engine in liters, the
cause the MIL (“Check Engine” lamp) to turn on. class of the vehicle, and the type of fuel metering system.
Aftermarket electronics, such as transceivers, stereos, There is also an illustrated emission components and
and anti-theft devices, may radiate EMI into the control vacuum hose schematic.
system if they are improperly installed. This may cause a This label is located in the engine compartment of every
false sensor reading and turn on the MIL (“Check Engine” vehicle. If the label has been removed it should be
lamp). replaced. It can be ordered from Isuzu Dealership.
Environment
Temporary environmental conditions, such as localized
Visual / Physical Engine Compartment
flooding, will have an effect on the vehicle ignition system. Inspection
If the ignition system is rain-soaked, it can temporarily Perform a careful visual and physical engine
cause engine misfire and turn on the MIL (“Check Engine” compartment inspection when performing any diagnostic
lamp). procedure or diagnosing the cause of an emission test
failure. This can often lead to repairing a problem without
further steps. Use the following guidelines when
performing a visual/physical inspection:
D Inspect all vacuum hoses for pinches, cuts, When a diagnostic test reports a fail result, the diagnostic
disconnections, and proper routing. executive records the following data:
D Inspect hoses that are difficult to see behind other D The diagnostic test has been completed since the last
components. ignition cycle.
D Inspect all wires in the engine compartment for proper D The fault identified by the diagnostic test is currently
connections, burned or chafed spots, pinched wires, active.
contact with sharp edges or contact with hot exhaust D The fault has been active during this ignition cycle.
manifolds or pipes.
D The operating conditions at the time of the failure.
Basic Knowledge of Tools Required Remember, a fuel trim DTC may be triggered by a list of
vehicle faults. Make use of all information available (other
NOTE: Lack of basic knowledge of this powertrain when DTCs stored, rich or lean condition, etc.) when
performing diagnostic procedures could result in an diagnosing a fuel trim fault.
incorrect diagnosis or damage to powertrain
components. Do not attempt to diagnose a powertrain Comprehensive Component Monitor
problem without this basic knowledge. Diagnostic Operation
A basic understanding of hand tools is necessary to effec- Comprehensive component monitoring diagnostics are
tively use this section of the Service Manual. required to monitor emissions-related input and output
powertrain components. The CARB OBD II
Serial Data Communications Comprehensive Component Monitoring List Of
Components Intended To illuminate MIL is a list of
components, features or functions that could fall under
Class II Serial Data Communications
this requirement.
Government regulations require that all vehicle
Input Components:
manufacturers establish a common communication
system. This vehicle utilizes the “Class II” Input components are monitored for circuit continuity and
communication system. Each bit of information can have out-of-range values. This includes rationality checking.
one of two lengths: long or short. This allows vehicle Rationality checking refers to indicating a fault when the
wiring to be reduced by transmitting and receiving signal from a sensor does not seem reasonable, i.e.
multiple signals over a single wire. The messages carried Throttle Position (TP) sensor that indicates high throttle
on Class II data streams are also prioritized. If two position at low engine loads or MAP voltage. Input
messages attempt to establish communications on the components may include, but are not limited to the
data line at the same time, only the message with higher following sensors:
priority will continue. The device with the lower priority D Vehicle Speed Sensor (VSS)
message must wait. The most significant result of this D Crankshaft Position (CKP) sensor
regulation is that it provides Scan tool manufacturers with D Throttle Position (TP) sensor
the capability to access data from any make or model
D Engine Coolant Temperature (ECT) sensor
vehicle that is sold.
The data displayed on other Scan tools will appear the D Camshaft Position (CMP) sensor
same, with some exceptions. Some Scan tools will only D Manifold Absolute Pressure (MAP) sensor
be able to display certain vehicle parameters as values D Mass Air Flow (MAF) sensor
that are a coded representation of the true or actual value. In addition to the circuit continuity and rationality check,
On this vehicle the Scan tool displays the actual values for the ECT sensor is monitored for its ability to achieve a
vehicle parameters. It will not be necessary to perform steady state temperature to enable closed loop fuel
any conversions from coded values to actual values. control.
Output Components:
On-Board Diagnostic (OBD II)
Output components are diagnosed for proper response to
control module commands. Components where
On-Board Diagnostic Tests functional monitoring is not feasible will be monitored for
A diagnostic test is a series of steps, the result of which is circuit continuity and out-of-range values if applicable.
a pass or fail reported to the diagnostic executive. When Output components to be monitored include, but are not
a diagnostic test reports a pass result, the diagnostic limited to, the following circuits:
executive records the following data: D Control module controlled EVAP Canister Purge
D The diagnostic test has been completed since the last Valve
ignition cycle. D Electronic Transmission controls
D The diagnostic test has passed during the current D A/C relays
ignition cycle.
D Cooling fan relay
D The fault identified by the diagnostic test is not
currently active. D VSS output
D MIL control
D Cruise control inhibit D EGR
Refer to PCM and Sensors in General Descriptions. D Catalyst monitoring
Passive and Active Diagnostic Tests Enable Criteria
A passive test is a diagnostic test which simply monitors a The term “enable criteria” is engineering language for the
vehicle system or component. Conversely, an active test, conditions necessary for a given diagnostic test to run.
actually takes some sort of action when performing Each diagnostic has a specific list of conditions which
diagnostic functions, often in response to a failed passive must be met before the diagnostic will run. “Enable
test. For example, the EGR diagnostic active test will criteria” is another way of saying “conditions required”.
force the EGR valve open during closed throttle decel The enable criteria for each diagnostic is listed on the first
and/or force the EGR valve closed during a steady state. page of the DTC description in Section 6E under the
Either action should result in a change in manifold heading “Conditions for Setting the DTC”. Enable criteria
pressure. varies with each diagnostic, and typically includes, but is
Intrusive Diagnostic Tests not limited to the following items:
This is any on-board test run by the Diagnostic D engine speed
Management System which may have an effect on D vehicle speed
vehicle performance or emission levels. D ECT
Warm-Up Cycle D MAF/MAP
A warm-up cycle means that engine at temperature must D barometric pressure
reach a minimum of 70°C (160°F) and rise at least 22°C
D IAT
(40°F) over the course of a trip.
D TP
Freeze Frame
D high canister purge
Freeze Frame is an element of the Diagnostic
Management System which stores various vehicle D fuel trim
information at the moment an emissions-related fault is D TCC enabled
stored in memory and when the MIL is commanded on. D A/C on
These data can help to identify the cause of a fault. Refer Trip
to Storing And Erasing Freeze Fame Data in this section
Technically, a trip is a key on-run-key off cycle in which all
for more detailed information.
the enable criteria for a given diagnostic are met, allowing
Failure Records the diagnostic to run. Unfortunately, this concept is not
Failure Records data is an enhancement of the OBD II quite that simple. A trip is official when all the enable
Freeze Frame feature. Failure Records store the same criteria for a given diagnostic are met. But because the
vehicle information as does Freeze Frame, but it will store enable criteria vary from one diagnostic to another, the
that information for any fault which is stored in on-board definition of trip varies as well. Some diagnostics are run
memory, while Freeze Frame stores information only for when the vehicle is at operating temperature, some when
emission-related faults that command the MIL on. the vehicle first starts up; some require that the vehicle be
cruising at a steady highway speed, some run only when
System Status and Drive Cycle for the vehicle is idle; some diagnostics function with the
Satisfying Federal Inspection/Maintenance TCC disable. Some run only immediately following a cold
(I/M 240) Regulations engine start-up.
I/M Ready Status means a signal or flag for each A trip then, is defined as a key on-run-key off cycle in
emission system test that had been set in the PCM. I/M which the vehicle was operated in such a way as to satisfy
Ready Status indicates that the vehicle on-board the enabling criteria for a given diagnostic, and this
emissions diagnostics have been run. I/M Ready Status diagnostic will consider this cycle to be one trip. However,
is not concerned whether the emission system passed or another diagnostic with a different set of enable criteria
failed the test, only that on-board diagnosis is complete. (which were not met) during this driving event, would not
Not all vehicles use all possible I/M flags. consider it a trip. No trip will occur for that particular
diagnostic until the vehicle is driven in such a way as to
Common OBD II Terms meet all the enable criteria.
Diagnostic The Diagnostic Executive
When used as a noun, the word diagnostic refers to any The Diagnostic Executive is a unique segment of
on-board test run by the vehicle’s Diagnostic software which is designed to coordinate and prioritize
Management System. A diagnostic is simply a test run on the diagnostic procedures as well as define the protocol
a system or component to determine if the system or for recording and displaying their results. The main
component is operating according to specification. There responsibilities of the Diagnostic Executive are listed as
are many diagnostics, shown in the following list: the following:
D Misfire D Commanding the MIL (“Check Engine” lamp) on and
D Oxygen sensors off
D Oxygen sensor heaters D DTC logging and clearing
D Freeze Frame data for the first emission related DTC D The diagnostic tests that are passed must occur
recorded within 375 RPM of the RPM data stored at the time the
D Non-emission related Service Lamp last test failed.
D Operating conditions Failure Records buffer, (the D Plus or minus ten (10) percent of the engine load that
number of records will vary) was stored at the time the last failed.
D Current status information on each diagnostic D Similar engine temperature conditions (warmed up or
warming up ) as those stored at the time the last test
D System Status (I/M ready)
failed.
The Diagnostic Executive records DTCs and turns on the
Meeting these requirements ensures that the fault which
MIL when emission-related faults occur. It can also turn
turned on the MIL has been corrected.
off the MIL if the conditions cease which caused the DTC
The MIL (“Check Engine” lamp) is on the instrument
to set.
panel and has the following function:
Diagnostic Information D It informs the driver that a fault affects vehicle
The diagnostic charts and functional checks are designed emission levels has occurred and that the vehicle
to locate a faulty circuit or component through a process should be taken for service as soon as possible.
of logical decisions. The charts are prepared with the D As a bulb and system check, the MIL will come “ON”
requirement that the vehicle functioned correctly at the with the key “ON” and the engine not running. When
time of assembly and that there are no multiple faults the engine is started, the MIL will turn “OFF.”
present. D When the MIL remains “ON” while the engine is
There is a continuous self-diagnosis on certain control running, or when a malfunction is suspected due to a
functions. This diagnostic capability is complemented by driveability or emissions problem, a Powertrain
the diagnostic procedures contained in this manual. The On-Board Diagnostic (OBD ll) System Check must be
language of communicating the source of the malfunction performed. The procedures for these checks are
is a system of diagnostic trouble codes. When a given in On-Board Diagnostic (OBD) System Check.
malfunction is detected by the control module, a These checks will expose faults which may not be
diagnostic trouble code is set and the Malfunction detected if other diagnostics are performed first.
Indicator Lamp (MIL) (“Check Engine” lamp) is
illuminated. DTC Types
Malfunction Indicator Lamp (MIL) Each DTC is directly related to a diagnostic test. The
The Malfunction Indicator Lamp (MIL) looks the same as Diagnostic Management System sets DTC based on the
the MIL you are already familiar with (“Check Engine” failure of the tests during a trip or trips. Certain tests must
lamp). However, OBD II requires that it illuminate under a fail two (2) consecutive trips before the DTC is set. The
strict set of guide lines. following are the four (4) types of DTCs and the
Basically, the MIL is turned on when the PCM detects a characteristics of those codes:
DTC that will impact vehicle emissions. D Type A
The MIL is under the control of the Diagnostic Executive. D Emissions related
The MIL will be turned on if an emissions-related D Requests illumination of the MIL of the first trip with a
diagnostic test indicates a malfunction has occurred. It fail
will stay on until the system or component passes the
D Stores a History DTC on the first trip with a fail
same test, for three consecutive trips, with no emissions
related faults. D Stores a Freeze Frame (if empty)
If the vehicle is experiencing a misfire malfunction which D Stores a Fail Record
may cause damage to the Three-Way Catalytic D Updates the Fail Record each time the diagnostic
Converter (TWC), the MIL will flash once per second. test fails
This will continue until the vehicle is outside of speed and D Type B
load conditions which could cause possible catalyst
D Emissions related
damage, and the MIL will stop flashing and remain on
steady. D “Armed” after one (1) trip with a fail
Extinguishing the MIL D “Disarmed” after one (1) trip with a pass
When the MIL is on, the Diagnostic Executive will turn off D Requests illumination of the MIL on the second
the MIL after three(3) consecutive trips that a “test consecutive trip with a fail
passed” has been reported for the diagnostic test that D Stores a History DTC on the second consecutive trip
originally caused the MIL to illuminate. with a fail (The DTC will be armed after the first fail)
Although the MIL has been turned off, the DTC will remain D Stores a Freeze Frame on the second consecutive
in the PCM memory (both Freeze Frame and Failure trip with a fail (if empty)
Records) until forty(40) warm-up cycles after no faults D Stores a Fail Record when the first test fails (not
have been completed. dependent on consecutive trip fails)
If the MIL was set by either a fuel trim or misfire-related D Updates the Fail Record each time the diagnostic
DTC, additional requirements must be met. In addition to test fails
the requirements stated in the previous paragraph, these
requirements are as follows:
(Some special conditions apply to misfire and fuel trim Storing and Erasing Freeze Frame Data and Failure
DTCs) Records
D Type C (if the vehicle is so equipped) Government regulations require that engine operating
D Non-Emissions related conditions be captured whenever the MIL is illuminated.
D Requests illumination of the Service Lamp or the The data captured is called Freeze Frame data. The
service message on the Drive Information Center Freeze Frame data is very similar to a single record of
(DIC) on the first trip with a fail operating conditions. Whenever the MIL is illuminated,
the corresponding record of operating conditions is
D Stores a History DTC on the first trip with a fail
recorded to the Freeze Frame buffer.
D Does not store a Freeze Frame Freeze Frame data can only be overwritten with data
D Stores Fail Record when test fails associated with a misfire or fuel trim malfunction. Data
D Updates the Fail Record each time the diagnostic from these faults take precedence over data associated
test fails with any other fault. The Freeze Frame data will not be
D Type D erased unless the associated history DTC is cleared.
Each time a diagnostic test reports a failure, the current
D Non-Emissions related
engine operating conditions are recorded in the Failure
D Not request illumination of any lamp Records buffer. A subsequent failure will update the
D Stores a History DTC on the first trip with a fail recorded operating conditions. The following operating
D Does not store a Freeze Frame conditions for the diagnostic test which failed typically
D Stores Fail Record when test fails include the following parameters:
D Updates the Fail Record each time the diagnostic D Air Fuel Ratio
test fails D Air Flow Rate
IMPORTANT: Only four Fail Records can be stored. D Fuel Trim
Each Fail Record is for a different DTC. It is possible that D Engine Speed
there will not be Fail Records for every DTC if multiple D Engine Load
DTCs are set.
D Engine Coolant Temperature
Special Cases of Type B Diagnostic Tests D Vehicle Speed
Unique to the misfire diagnostic, the Diagnostic Executive D TP Angle
has the capability of alerting the vehicle operator to
D MAP/BARO
potentially damaging levels of misfire. If a misfire
condition exists that could potentially damage the D Injector Base Pulse Width
catalytic converter as a result of high misfire levels, the D Loop Status
Diagnostic Executive will command the MIL to “flash” at a Intermittent Malfunction Indicator Lamp
rate of once per seconds during those the time that the In the case of an “intermittent” fault, the MIL (“Check
catalyst damaging misfire condition is present. Engine” lamp) may illuminate and then (after three trips)
Fuel trim and misfire are special cases of Type B go “OFF”. However, the corresponding diagnostic trouble
diagnostics. Each time a fuel trim or misfire malfunction is code will be stored in the memory. When unexpected
detected, engine load, engine speed, and engine coolant diagnostic trouble codes appear, check for an intermittent
temperature are recorded. malfunction.
When the ignition is turned off, the last reported set of A diagnostic trouble code may reset. Consult the
conditions remain stored. During subsequent ignition “Diagnostic Aids” associated with the diagnostic trouble
cycles, the stored conditions are used as reference for code. A physical inspection of the applicable sub-system
similar conditions. If a malfunction occurs during two most often will resolve the problem.
consecutive trips, the Diagnostic Executive treats the
failure as a normal Type B diagnostic, and not use the Data Link Connector (DLC)
stored conditions. However, if a malfunction occurs on The provision for communication with the control module
two non-consecutive trips, the stored conditions are is the Data Link Connector (DLC). It is located at the
compared with the current conditions. The MIL will then lower left of the instrument panel behind a small square
illuminate under the following conditions: cover. The DLC is used to connect to the Tech 2 Scan
D When the engine load conditions are within 10% of Tool. Some common uses of the Tech 2 are listed below:
the previous test that failed. D Identifying stored Diagnostic Trouble Codes (DTCs).
D Engine speed is within 375 rpm, of the previous test D Clearing DTCs.
that failed. D Performing output control tests.
D Engine coolant temperature is in the same range as D Reading serial data.
the previous test that failed.
4. Monitor the DTC status information for the DTC which
has been diagnosed until the diagnostic test
associated with that DTC runs.
Following these steps are very important in verifying
repairs on OBD ll systems. Failure to follow these steps
could result in unnecessary repairs.
Reading Diagnostic Trouble Codes Using

The Tech 2 Scan Tool
The procedure for reading diagnostic trouble code(s) is to
use a diagnostic Scan Tool. When reading DTC(s), follow
instructions supplied by tool manufacturer.
Clearing Diagnostic Trouble Codes
IMPORTANT: Do not clear DTCs unless directed to do
so by the service information provided for each diagnostic
procedure. When DTCs are cleared, the Freeze Frame
and Failure Record data which may help diagnose an
intermittent fault will also be erased from memory.
TS24064
If the fault that caused the DTC to be stored into memory
has been corrected, the Diagnostic Executive will begin to
Decimal/Binary/Hexadecimal Conversions count the “warm-up” cycles with no further faults
Beginning in 1996, Federal Regulations require that all detected, the DTC will automatically be cleared from the
auto manufacturers selling vehicles in the United States PCM memory.
provide Scan Tool manufacturers with software To clear Diagnostic Trouble Codes (DTCs), use the
information to display vehicle operating parameters. All diagnostic Scan Tool “clear DTCs” or “clear information”
Scan Tool manufacturers will display a variety of vehicle function. When clearing DTCs follow instructions
information which will aid in repairing the vehicle. Some supplied by the tool manufacturer.
Scan Tools will display encoded messages which will aid When a Scan Tool is not available, DTCs can also be
in determining the nature of the concern. The method of cleared by disconnecting one of the following sources for
encoding involves the use of a two additional numbering at least thirty (30) seconds.
systems: Binary and Hexadecimal. NOTE: To prevent system damage, the ignition key must
The binary number system has a base of two numbers. be “OFF” when disconnecting or reconnecting battery
Each digit is either a 0 or a 1. A binary number is an eight power.
digit number and is read from right to left. Each digit has a D The power source to the control module. Examples:
position number with the farthest right being the 0 position fuse, pigtail at battery PCM connectors etc.
and the farthest left being the 7 position. The 0 position,
D The negative battery cable. (Disconnecting the
when displayed by a 1, indicates 1 in decimal. Each
negative battery cable will result in the loss of other
position to the left is double the previous position and on-board memory data, such as preset radio tuning).
added to any other position values marked as a 1.
A hexadecimal system is composed of 16 different alpha
numeric characters. The alpha numeric characters used
are numbers 0 through 9 and letters A through F. The
hexadecimal system is the most natural and common
approach for Scan Tool manufacturers to display data
represented by binary numbers and digital code.
Verifying Vehicle Repair

Verification of vehicle repair will be more comprehensive
for vehicles with OBD II system diagnostic. Following a
repair, the technician should perform the following steps:
1. Review and record the Fail Records and/or Freeze
Frame data for the DTC which has been diagnosed
(Freeze Frame data will only be stored for an A or B
type diagnostic and only if the MIL has been
requested).
2. Clear DTC(s).
3. Operate the vehicle within conditions noted in the Fail
Records and/or Freeze Frame data.
Tech 2
recommended to use the Tech 2 Scan Tool. Please refer
to the Tech 2 user guide.
901RW180
Legend (3) SAE 16/19 Adaptor

(1) PCMCIA Card (4) DLC Cable
(2) RS 232 Loop Back Connector (5) Tech–2
Tech 2 Features 6. Turn on the vehicle ignition.
1. Tech 2 is a 12 volt system. Do not apply 24 volts. 7. Power the Tech 2 ON and verify the Tech 2 power up
display.
2. After connecting and/or installing the Vehicle
Communications Interface (VCI) module, PCMCIA
card and DLC connector to the Tech 2, connect the
tool to the vehicle DLC.
3. Make sure the Tech 2 is powered OFF when
removing or installing the PCMCIA card.
4. The PCMCIA card has a capacity of 10 Megabytes
which is 10 times greater than the memory of the Tech
1 Mass Storage Cartridge.
5. The Tech 2 has the capability of two snapshots.
6. The PCMCIA card is sensitive to magnetism and
static electricity, so care should be taken in the
handling of the card.
7. The Tech 2 can plot a graph when replaying a
snapshot.
8. Always return to the Main Menu by pressing the EXIT
key several times before shutting down.
9. To clear Diagnostic Trouble Codes (DTCs), open
Application Menu and press “F1: Clear DTC Info”.
060RW009
Getting Started NOTE: The RS232 Loop back connector is only to use for
D Before operating the Isuzu PCMCIA card with the diagnosis of Tech 2. Refer to user guide of the Tech 2.
Tech 2, the following steps must be performed:
1. The Isuzu 2000 System PCMCIA card (1) inserts into
the Tech 2 (5).
(4).
3. Connect the DLC cable to the Tech 2 (5)
DLC.
821RW021
Operating Procedure (For Example)
The power up screen is displayed when you power up the
tester with the Isuzu systems PCMCIA card. Follow the
operating procedure below.
060RY00072
060RY027
Menu
D The following table shows which functions are used
for the available equipment versions.
060RW223
The following is a brief description of each of the sub

menus in DTC Info and DTC. The order in which they
060RY00073
appear here is alphabetical and not necessarily the way
they will appear on the Tech 2.
DTC Modes
DTC Information Mode
Use the DTC info mode to search for a specific type of
stored DTC information.
DTC Status
This selection will display any DTCs that have not run
during the current ignition cycle or have reported a test
failure during this ignition up to DTCs. DTC tests which
run and pass will cause that DTC number to be removed
from Tech 2 screen.
Fail This Ignition
This selection will display all DTCs that have failed during
the present ignition cycle.
History
This selection will display only DTCs that are stored in the
PCM’s history memory. It will display all type A and B
DTCs that have requested the MIL and have failed within
the last 40 warm-up cycles. In addition, it will display all
type C and type D DTCs that have failed within the last 40
060RY00074
warm-up cycles.
On OBD II vehiles there are options available in Tech 2 Last Test Failed
DTC mode to display the enhanced information available. This selection will display only DTCs that have failed the
After selecting DTC, the following menu appears: last time the test run. The last test may have run during a
1. Read DTC Info by Priority previous ignition cycle if a type A or type B DTC is
2. Freeze Frame displayed. For type C and type D DTCs, the last failure
3. Fail Records (not all applications) must have occurred during the current ignition cycle to
appear as Last Test Fail.
4. DTC Info
MILSVC or Message Request
5. Clear Info
This selection will display only DTCs that are requesting
the MIL. Type C and type D DTCs cannot be displayed
using this option. This selection will report type B DTCs
only after the MIL has been requested.
Not Run Since Code Cleared 4. Select F0:Lamps Test in the Miscellaneous Test.
This option will display up to DTCs that have not run since
the DTCs were last cleared. Since any displayed DTCs
have not run, their condition (passing or failing) is
unknown.
Test Failed Since Code Cleared
This selection will display all active and history DTCs that
have reported a test failure since the last time DTCs were
cleared. DTCs that last failed more than 40 warm-up
cycles before this option is selected will not be displayed.
Miscellaneous Test
This test consists of eight menus-Lights, Relays, EVAP,
Fuel System, Instruments, EGR Control, Variable Intake
Manifold Solenoid, and Injector Balance Tests.
In these tests, Tech 2 sends operating signals to the
systems to confirm their operations thereby to judge the
normality of electric circuits.
To judge intermittent trouble,
1. Confirm DTC freeze frame data, and match the
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freeze frame data as test conditions with the data list
displayed by Miscellaneous Test. 5. Select F0:Malfunction Indicator Lamp.
2. Confirm DTC setting conditions, and match the
setting conditions as test conditions with the data list
displayed by Miscellaneous Test.
3. Refer to the latest Service Bulletin.
Check to see if the Latest software is released or not.
And then Down Load the LATEST PROGRAMMED
SOFTWARE to the replacement PCM.
Lamps Test
This test is conducted check MIL, Up Shift Lamp, Low
Fuel Lamp, Reduced Power Lamp and Cruise Control
Lamp for its working.
Tech2 must be used for this test.
Test Procedure:
1. Connect Tech 2 to the vehicle DLC.
2. Run the Engine at idle.
3. Select F3: Miscellaneous Test in the Application
Menu.
060RY00091
6. Push”On” soft key.

7. Make sure Lamp illuminates.
8. If lamp illuminates, the Lamp is operating correctly.
060RY00075
9. Select F2: Up Shift Lamp 17. Select F3:Reduced Power Lamp
060RY00076 060RY00077
10. Push “On” of soft key. 18. Push ”On” of soft key.
11. Make sure Lamp illuminates. 19. Make sure Lamp illuminates.
12. If Lamp illuminates, the Lamp is operating correctly. 20. If Lamp illuminates, the Lamp is operating correctly.
13. Select F2:Low Fuel Lamp 21. Select F5:Cruise Control Lamp
060RY00092 060RY00078
14. Push ”On” of soft key. 22. Push ”On” of soft key.
15. Make sure Lamp illuminates. 23. Make sure Lamp illuminates.
16. If Lamp illuminates, the Lamp is operating correctly. 24. If Lamp illuminates, the Lamp is operating correctly.
Relays Test 5. Select F0:Fuel Pump Relay.
This test is conducted to check Fuel Pump Relay and A/C
Clutch for proper operation.
Tech 2 must be used for this test.
Test Procedure:
2. Ignition SW is “On”.
Menu.
060RX021
6. Push “On” soft key.
060RY00075
4. Select F1:Relay Test in the Miscellaneous Test.
060RY00093
7. Control Fuel Pump Relay and check data list.

8. If the data list changes, the Fuel Pump Relay is
normal.
9. Select F1:A/C Clutch Relay.
060RY00081
11. Turn on Air Condtioning. 4. Select F2: EVAP Test in the Miscellaneous Test.
060RY00094 060RY00082
12. Turn “On” and “Off” A/C Switch. 5. Select F0: Purge Solenoid.
13. Contol A/C Clutch Relay and check data list.
14. If the data list changes, the Fuel Pump Relay is
normal.
EVAP Test
This test is conducted to check EVAP system for its power
operation.
Test Procedure:
Menu.
060RX025
060RY00075
6. Push “Decrease” or “Increase” soft key. 11. Push “On” or “Off” soft key.
060RY00095 060RY00096
7. Control EVAP Purge Solenoid and check a data list. 12. Control EVAP Vent Solenoid and check data list.
8. If the data list changes, the Purge Solenoid is normal. 13. If the data list changes, the EVAP Vent Solenoid is
9. Turn engine off, turn ignition SW “On”. normal.
10. Select F1:EVAP Vent Solenoid.
Fuel System Test
This test is conducted check Fuel system for proper
operation.
Test Procedure:
Menu.
060RX025
060RY00075
4. Select F3: Fuel System in the Miscellaneous Menu. 6. Push “Disable” or “Enable” soft key.
060RY00083 060RY00097
5. Select F0: Fuel Trim Enable. 7. Control Fuel Trim and check data list.
8. If data list changes, the Fuel Trim is normal.
9. Select F1: Fuel Trim Reset.
060RY00079
060RY00079
10. Push “Reset” of soft key. 13. Push “Open Loop” or “Closed Loop” soft key.
060RY00098 060RY00099
11. Select F2: O2-Loop status. 14. Control O2-Loop and check data list.
15. If data list changes, the O2-Loop is normal.
Instruments Test
This test is conducted check Instruments for proper
operation.
Test Procedure:
Menu.
060RY00079
12. This test is check the “Closed Loop Status”

performance.
060RY00075
4. Select F4: Instruments in the Miscellaneous Menu. 6. Push “Decrease” or “Increase” soft key.
060RY00106 060RY00100
5. Select F0: Fuel Gauge level. 7. Control Fuel Level and check data list.
8. If data list and Fuel gauge meter changes, Fuel
Gauge level is normal.
9. Select F1: Tachometer Control Test.
060RY00107
060RY00107
10. Push “Inactive” or “active” soft key. 4. Select F5: EGR Control Test in the Miscellaneous
Test.
060RY00101
11. Control tachometer and data list. 060RY00084
12. If data list and meter changes, the tachometer control 5. Control EGR Valve and check data list.
is normal.
EGR Control Test

This test is conducted check EGR valve for proper
operation.
Test Procedure:
Menu.
060RY00103
6. If data list changes, the EGR Contol is normal.
Variable Intake Manifold Solenoid Test

This test is conducted check VIM Solenoid for proper
operation.
Test Procedure:
060RY00075
2. Ignition SW is “On”. 4. Select F6: Variable Intake Manifold Solenoid Test.
060RY00104 060RY00085
3. Select F3: Miscellaneous Test in the Application 5. Push “On” or “Off” of soft key.
Menu.
060RX028
060RY00075 6. Control VIM Solenoid check data list.

7. If data list changes, the VIM Solenoid is normal.
Injector Balance Test 5. Select injector number and push “injector off” soft key.
This test is conducted to make sure the appropriate
electric signals are being sent to injectors Nos. 1–6.
Test Procedure:
Menu.
060RY00105
6. Make sure of engine speed change.

7. If engine speed changes, the injector electric circuit is
normal.
If engine speed does not change, the injector electric
circuit or the injector itself is not normal.
Plotting Snapshot Graph

060RY00075
This test selects several necessary items from the data
4. Select F7: Injector Balance Test in the Miscellaneous list to plot graphs and makes data comparison on a long
Test. term basis. It is an effective test particularly in emission
related evaluations.
060RY00086
060RX037
For trouble diagnosis, you can collect graphic data (snap

shot) directly from the vehicle.
You can replay the snapshot data as needed. Therefore,
accurate diagnosis is possible, even though the vehicle is
not available.
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)
D06RY00167
Flow Chart for Snapshot Replay (Plotting Graph)
060RX040
Primary System-Based Diagnostic HO2S Heater

Heated oxygen sensors are used to minimize the amount
Primary System-Based Diagnostic of time required for closed loop fuel control to begin
There are primary system-based diagnostics which operation and to allow accurate catalyst monitoring. The
evaluate system operation and its effect on vehicle oxygen sensor heater greatly decreases the amount of
emissions. The primary system-based diagnostics are time required for fuel control sensors (Bank 1 HO2S 1 and
listed below with a brief description of the diagnostic Bank2 HO2S 1) to become active. Oxygen sensor
function: heaters are required by catalyst monitor and sensor
(Bank 1 HO2S 2 and Bank 2 HO2S 2) to maintain a
Oxygen Sensor Diagnosis
sufficiently high temperature which allows accurate
The fuel control heated oxygen sensors (Bank 1 HO2S 1 exhaust oxygen content readings further away from the
and Bank 2 HO2S 1) are diagnosed for the following engine.
conditions:
D Heater performance (time to activity on cold start) Catalyst Monitor Heated Oxygen Sensors
D Slow response and Diagnostic Operation
D Response time (time to switch R/L or L/R)
D Inactive signal (output steady at bias voltage –
approx. 450 mV)
D Signal fixed high
D Signal fixed low
The catalyst monitor heated oxygen sensors (Bank 1
HO2S 2 and Bank 2 HO2S 2) are diagnosed for the
following conditions:
D Heater performance (time to activity on cold start).
D Signal fixed low during steady state conditions or
power enrichment (hard acceleration when a rich
mixture should be indicated).
D Signal fixed high during steady state conditions or
deceleration mode (deceleration when a lean mixture
should be indicated).
D Inactive sensor (output steady at approx. 438 mV).
If the oxygen sensor pigtail wiring, connector or terminal
are damaged, the entire oxygen sensor assembly must
be replaced. DO NOT attempt to repair the wiring, TS24067
connector or terminals. In order for the sensor to function To control emissions of hydrocarbons (HC), carbon
properly, it must have clean reference air provided to it. monoxide (CO), and oxides of nitrogen (NOx), a
This clean air reference is obtained by way of the oxygen three-way catalytic converter is used. The catalyst within
sensor wire(s). Any attempt to repair the wires, connector the converter promotes a chemical reaction which
or terminals could result in the obstruction of the oxidizes the HC and CO present in the exhaust gas,
reference air and degrade oxygen sensor performance. converting them into harmless water vapor and carbon
Refer to On-Vehicle Service, Heated Oxygen Sensors in dioxide. The catalyst also reduces NOx, converting it to
this section. nitrogen. The PCM has the ability to monitor this process
using the pre-catalyst and post-catalyst heated oxygen
Fuel Control Heated Oxygen Sensor sensors. The pre-catalyst sensor produces an output
The main function of the fuel control heated oxygen signal which indicates the amount of oxygen present in
sensors is to provide the control module with exhaust the exhaust gas entering the three-way catalytic
stream oxygen content information to allow proper fueling converter. The post-catalyst sensor produces an output
and maintain emissions within mandated levels. After it signal which indicates the oxygen storage capacity of the
reaches operating temperature, the sensor will generate catalyst; this in turn indicates the catalyst’s ability to
a voltage, inversely proportional to the amount of oxygen convert exhaust gases efficiently. If the catalyst is
present in the exhaust gases. The control module uses operating efficiently, the pre-catalyst signal will be far
the signal voltage from the fuel control heated oxygen more active than that produced by the post-catalyst
sensors while in closed loop to adjust fuel injector pulse sensor.
width. While in closed loop, the PCM can adjust fuel In addition to catalyst monitoring, the heated oxygen
delivery to maintain an air/fuel ratio which allows the best sensors have a limited role in controlling fuel delivery. If
combination of emission control and driveability. The fuel the sensor signal indicates a high or low oxygen content
control heated oxygen sensors are also used to for an extended period of time while in closed loop, the
determine catalyst efficiency. PCM will adjust the fuel delivery slightly to compensate.
D For the 3.5L w/automatic transmission, the Aftermarket HO2S characteristics may be different from
pre-catalyst sensor are designated Bank 1 HO2S 1 the original equipment manufacturer sensor. This may
and Bank 2 HO2S 1. The post-catalyst sensors are lead to a false pass or a false fail of the catalyst monitor
Bank 1 HO2S 2 and Bank 2 HO2S 2. diagnostic. Similarly, if an aftermarket catalyst does not
Catalyst Monitor Outputs contain the same amount of cerium as the original part,
The catalyst monitor diagnostic is sensitive to the the correlation between oxygen storage and conversion
following conditions: efficiency may be altered enough to set a false DTC.
D Exhaust leaks Evaporative Emission (EVAP) Purge
D HO2S contamination System Vacuum Switch
D Alternate fuels The EVAP system uses a switch located in the purge line
Exhaust system leaks may cause the following: between the canister and the purge valve to detect when
D Preventing a degraded catalyst from failing the purge is occurring. This switch senses the flow from the
diagnostic. engine through the purge valve. When no purge is
D Causing a false failure for a normally functioning present, the switch is closed, applying a 12 volt signal to
catalyst. the control module as a NO PURGE signal. When
D Preventing the diagnostic from running. canister purging occurs, the switch opens, interrupting
Some of the contaminants that may be encountered are the 12 volt signal to the control module. A Tech 2 display
phosphorus, lead, silica, and sulfur. The presence of will indicate that purge is occurring.
these contaminants will prevent the TWC diagnostic from Clogging of the canister fresh air vent could allow the
functioning properly. purge hose between the switch and canister to trap
vacuum with the purge valve closed. This would result in
Three-Way Catalyst Oxygen Storage Capacity
a diagnostic indication of a purge valve stuck open or a
The Three-Way catalyst (TWC) must be monitored for vacuum switch failure. Similarly, leaks or blockages in the
efficiency. To accomplish this, the control module purge hoses may result in misdiagnosis of the purge valve
monitors the pre-catalyst HO2S and post-catalyst HO2S or vacuum switch.
oxygen sensors. When the TWC is operating properly, When servicing a purge valve diagnostic trouble code,
the post-catalyst oxygen sensor will have significantly check the canister fresh air vent, vacuum switch and the
less activity than the pre-catalyst oxygen sensor. The integrity of all purge hoses prior to servicing the valve.
TWC stores and releases oxygen as needed during its (Refer to EVAP Vacuum Switch in On-Vehicle Service
normal reduction and oxidation process. The control Procedures in this section.)
module will calculate the oxygen storage capacity using
the difference between the pre-catalyst and post catalyst Misfire Monitor Diagnostic Operation
oxygen sensor’s voltage levels. If the activity of the
post-catalyst oxygen sensor approaches that of the Misfire Monitor Diagnostic Operation
pre-catalyst oxygen sensor, the catalyst’s efficiency is
degraded. Misfire is monitored as a function of the combustion
Stepped or staged testing level allow the control module quality (CQ) signals generated from the ignition current
to statistically filter test information. This prevents falsely sense system. Combustion signals represent the degree
passing or falsely failing the oxygen storage capacity test. of combustion in each cylinder. Misfire is detected when
The calculations performed by the on-board diagnostic the combustion signal is below a predetermined value.
system are very complex. For this reason, post catalyst The misfire ratio is calculated once every 100 engine
oxygen sensor activity should not be used to determine cycles. For example, on a 6-cylinder engine, 600 ignition
oxygen storage capacity unless directed by the service plug sparks occur every 100 cycles and if a misfire occurs
manual. 12 times during that time, the misfire is 12/600 × 100 = 2
Two stages are used to monitor catalyst efficiency. %.
Failure of the first stage will indicate that the catalyst
requires further testing to determine catalyst efficiency.
Misfire Counters
The seconds stage then looks at the inputs for the pre and Whenever a cylinder misfires, the misfire diagnostic
post catalyst HO2S sensors more closely before counts the misfire and notes the crankshaft position at the
determining if the catalyst is indeed degraded. This time the misfire occurred. These “misfire counters” are
further statistical processing is done to increase the basically a file on each engine cylinder. A current and a
accuracy of oxygen storage capacity type monitoring. history misfire counter are maintained for each cylinder.
Failing the first (stage 1) test DOES NOT indicate a failed The misfire current counters (Misfire Cur #1-6) indicate
catalyst. The catalyst may be marginal or the fuel sulfur the number of firing events out of the last 100 cylinder
content could be very high. firing events which were misfires. The misfire current
counter will display real time data without a misfire DTC
stored. The misfire history counters (Misfire Hist #1-6)
indicate the total number of cylinder firing events which
were misfires. The misfire history counters will display 0
until the misfire diagnostic has failed and a DTC P0300 is
set. Once the misfire DTC P0300 is set, the misfire
history counters will be updated every 100 cylinder firing vacuum leak or rough idle due to a large vacuum leak)
events. A misfire counter is maintained for each cylinder. while it operates fine at other times. No fuel trim DTC
If the misfire diagnostic reports a failure, the diagnostic would set (although an engine idle speed DTC or HO2S
executive reviews all of the misfire counters before DTC may set). Use the Tech 2 to observe fuel trim counts
reporting DTC. This way, the diagnostic executive while the problem is occurring.
reports the most current information. A fuel trim DTC may be triggered by a number of vehicle
When crankshaft rotation is erratic, a misfire condition will faults. Make use of all information available (other DTCs
be detected. Because of this erratic condition, the data stored, rich or lean condition, etc.) when diagnosing a fuel
that is collected by the diagnostic can sometimes trim fault.
incorrectly identify which cylinder is misfiring. Misfires are
counted from more than one cylinder. Cylinder #1 has the Fuel Trim Cell Diagnostic Weights
majority of counted misfires. In this case, the Misfire No fuel trim DTC will set regardless of the fuel trim counts
Counters would identify cylinder #1 as the misfiring in cell 0 unless the fuel trim counts in the weighted cells
cylinder. The misfires in the other counters were just are also outside specifications. This means that the
background noise caused by the erratic misfire rotation of vehicle could have a fuel trim problem which is causing a
the crankshaft. If the number of accumulated misfires is problem under certain conditions (i.e. engine idle high due
sufficient for the diagnostic to identify a true misfire, the to a small vacuum leak or rough due to a large vacuum
diagnostic will set DTC P0300 – Misfire Detected. leak) while it operates fine at other times. No fuel trim
Use diagnostic equipment to monitor misfire counter data DTC would set (although an engine idle speed DTC or
on OBD II-compliant vehicles. Knowing which specific HO2S DTC may set). Use the Tech 2 to observe fuel trim
cylinder(s) misfired can lead to the root cause, even when counts while the problem is occurring.
dealing with a multiple cylinder misfire. Using the
information in the misfire counters, identify which
cylinders are misfiring. If the counter indicate cylinders
numbers 1 and 4 misfired, look for a circuit or component
common to both cylinders number 1 and 4.
Misfire counter information is located in the “Eng.” menu,
“Misfire Data” sub-menu of the data list.
The misfire diagnostic may indicate a fault due to a
temporary fault not necessarily caused by a vehicle
emission system malfunction. Examples include the
following items:
D Contaminated fuel
D Low fuel
D Fuel-fouled spark plugs
D Basic engine fault
Fuel Trim System Monitor Diagnostic

Operation
Fuel Trim System Monitor Diagnostic
Operation
This system monitors the averages of short-term and
long-term fuel trim values. If these fuel trim values stay at
their limits for a calibrated period of time, a malfunction is
indicated. The fuel trim diagnostic compares the
averages of short-term fuel trim values and long-term fuel
trim values to rich and lean thresholds. If either value is
within the thresholds, a pass is recorded. If both values
are outside their thresholds, a rich or lean DTC will be
recorded.
The fuel trim system diagnostic also conducts an intrusive
test. This test determines if a rich condition is being
caused by excessive fuel vapor from the EVAP canister.
In order to meet OBD II requirements, the control module
uses weighted fuel trim cells to determine the need to set
a fuel trim DTC. A fuel trim DTC can only be set if fuel trim
counts in the weighted fuel trim cells exceed
specifications. This means that the vehicle could have a
fuel trim problem which is causing a problem under
certain conditions (i.e., engine idle high due to a small
On-Board Diagnostic (OBD II) System Check
D06RY00053
Circuit Description 2.The RPL (“Reduced Power lamp”) should be “ON”

The on-board diagnostic system check is the starting steady with the ignition “ON ”engine “OFF.”If not,
the “No RPL”chart should be used to isolate the
point for any driveability complaint diagnosis. Before
malfunction.
using this procedure, perform a careful visual/physical
check of the PCM and engine grounds for cleanliness and 3.Checks the Class 2 data circuit and ensures that the
tightness. PCM is able to transmit serial data.
The on-board diagnostic system check is an organized 4.This test ensures that the PCM is capable of
approach to identifying a problem created by an controlling the MIL (“Check Engine lamp”) and the
electronic engine control system malfunction. MIL (“Check Engine lamp”) driver circuit is not
shorted to ground.
Diagnostic Aids 5.This test ensures that the PCM is capable of
An intermittent may be caused by a poor connection, controlling the RPL (“Reduced Powere lamp”) and
rubbed–through wire insulation or a wire broken inside the the RPL (“Reduced Powere lamp”) driver circuit is
insulation. Check for poor connections or a damaged not shorted to ground.
harness. Inspect the PCM harness and connector for 7.Check the DTCs (System ,Volts Supply circuit).
improper mating, broken locks, improperly formed or
8.Check the DTCs (PCM{Software} detect Errors).
damaged terminals, poor terminal-to-wire connection,
and damaged harness. 10.If the engine will not start, the Cranks But Will Not
Run chart should be used to diagnose the condition.
Test Description 13.A Tech 2 parameter which is not within the typical
Number(s) below refer to the step number(s) on the range may help to isolate the area which is causing
Diagnostic Chart: the problem.
1.The MIL (“Check Engine lamp”) should be “ON” 14.This vehicle is equipped with a PCM which utilizes
steady with the ignition “ON ”engine “OFF.”If not, an electrically erasable programmable read only
the “No MIL”chart should be used to isolate the memory (EEPROM). When the PCM is replaced,
malfunction. the new PCM must be programmed. Refer to PCM
Replacement and Programming Procedures in
Powertrain Control Module (PCM) and Sensors of
this section.
On-Board Diagnostic (OBD II) System Check

1 1. Ignition “ON,”engine “OFF.”
2. Observe the malfunction indicator lamp (MIL or Go to No
“Check Engine lamp”). MIL(“Check
Is the MIL (“Check Engine lamp”)“ON?” — Go to Step 2 Engine lamp”)
2 1. Ignition “ON,”engine “OFF.”
Go to No
2. Observe the malfunction indicator lamp (“Reduced RPL(“Reduce
Power lamp”). d Power
Is the MIL (“Reduced Power lamp”) “ON?” — Go to Step 3 lamp”)
3 1. Ignition “OFF.”
2. Install Tech 2.
3. Ignition “ON.”
4. Attempt to display PCM engine data with the
Tech 2.
Does the Tech 2 display PCM data? — Go to Step 4 Go to Step 12
4 1. Using the Tech 2 output tests function, select MIL
(“Check Engine lamp”) control and command the
MIL (“Check Enginelamp”) “OFF.” Go to
MIL(“Check
2. Observe the MIL (“Check Engine lamp”). Engine lamp”)
Did the MIL (“Check Engine lamp”) turn “OFF?” — Go to Step 5 On Steady
5 1. Using the Tech 2 output tests function, select MIL
(“Reduced Power lamp”) control and command the Go to
MIL (“Reduced Power lamp”) “OFF.” RPL(“Reduce
d Power
2. Observe the MIL (“Reduced Power lampp”). lamp”)On
Did the MIL (“Reduced Power lamp”) turn “OFF?” — Go to Step 6 Steady
6 Select “Display DTCs” with the Tech 2.
Are any DTCs stored? — Go to Step 7 Go to Step 11
7 Following below the DTCs stored:
P0562,P0563,P0601,P0602,P0604,P0606,P1625,P1
Go to
635,P1639,P1640, 1650
applicable
— DTC table Go to Step 8
P1514, P1515, P1516, P1523, P1125, P1290, P1295,
Go to
P1299
applicable
1. P0425, P0106, P0107, P1107, P0401, P1404,
P0405, P1120, P1221, P1515, P1516, P1275,
P1635, P1271, P1273, P1285, P1272 Go to
“Multiple
2. PCM
P0336,P0337,P0341,P0342,P1220,P1515,P1221, Information
P1516,P1280,P1639,P1271,P1272 sensor DTCs
— Set” Go to Step 10
10 Attempt to start the engine. Go to Cranks
But Will Not
Did the engine start and continue to run?
— Go to Step 6 Run
On-Board Diagnostic (OBD II) System Check (Cont'd)

11 Compare PCM data values displayed on the Tech 2 to Refer to
the typical engine scan data values. indicated
Component
Are the displayed values normal or close to the typical
Go to System
values?
— Symptom Checks
12 1. Ignition “OFF,” disconnect the PCM.
2. Ignition “ON,” engine “OFF.”
3. Check the Class 2 data circuit for an open, short to
ground, or short to voltage. Also, check the DLC
ignition feed circuit for an open or short to ground
and the DLC ground circuit for an open.
4. If a problem is found, repair as necessary.
Was a problem found? — Go to Step 2 Go to Step 13
13 1. Attempt to reprogram the PCM. Refer to Powertrain
Control Module (PCM) in On-Vehicle Service.
2. Attempt to display PCM data with the Tech 2.
Does the Tech 2 display PCM engine data? — Go to Step 2 Go to Step 14
14 Replace the PCM.
IMPORTANT: The replacement PCM must be
programmed. Refer to ON-Vehicle Service in Power
Control Module and Sensors for procedures.
And also refer to latest Service Bulletin. Check to see
if the latest software is released or not. And then Down
Load the LATEST PROGRMMED SOFTWARE to the
replasement PCM.
A/C Clutch Control Circuit Diagnosis
D06RY00159
Circuit Description D The engine coolant temperature (ECT) is greater

When air conditioning and blower fan are selected, and if than 125 °C (257 °F).
the system has a sufficient refrigerant charge, a 12-volt D The intake air temperature (IAT) is less than 5°C
signal is supplied to the A/C request input of the (41°F).
powertrain control module (PCM). The A/C request D The power steering pressure switch signals a high
signal may be temporarily canceled during system pressure condition.
operation by the electronic thermostat in the evaporator
case. When the A/C request signal is received by the Diagnostic Aids
PCM, the PCM supplies a ground from the compressor To diagnose an the intermittent fault, check for following
clutch relay if the engine operating conditions are within conditions:
acceptable ranges. With the A/C compressor relay D Poor connection at the PCM–Inspect connections for
energized, voltage is supplied to the compressor clutch backed-out terminals, improper mating, broken locks,
coil. improperly formed or damaged terminals, and poor
The PCM will enable the compressor clutch to engage terminal-to-wire connection.
whenever A/C has been selected with the engine running, D Damaged harness–Inspect the wiring harness for
unless any of the following conditions are present: damage. If the harness appears to OK, observe the
D The throttle is greater than 90%. A/C clutch while moving connectors and wiring
D The ignition voltage is below 10.5 volts. harnesses related to the A/C. A sudden clutch
D The engine speed is greater than 4500 RPM for 5 malfunction will indicate the source of the intermittent
seconds or 5400 RPM. fault.
A/C Clutch Diagnosis 3. This a test determine is the problem is with the
This chart should be used for diagnosing the electrical refrigerant system. If the switch is open, A/C
pressure gauges will be used to determine if the
portion of the A/C compressor clutch circuit. A Tech 2 will
pressure switch is faulty or if the system is partially
be used in diagnosing the system. The Tech 2 has the
discharged or empty.
ability to read the A/C request input to the PCM. The
Tech 2 can display when the PCM has commanded the 4. Although the normal complaint will be the A/C clutch
A/C clutch “ON.” The Tech 2 should have the ability to failing to engage, it is possible for a short circuit to
override the A/C request signal and energize the A/C cause the clutch to run when A/C has not been
compressor relay. selected. This step is a test for that condition.
7. There is an extremely low probability that both relays
Test Description will fail at the same time, so the substitution process
IMPORTANT: Do not engage the A/C compressor is one way to check the A/C Thermostat relay. Use
clutch with the engine running if an A/C mode is not a known good relay to do a substitution check.
selected at the A/C control switch.
The numbers below refer to the step numbers on the
Diagnostic Chart:
A/C Clutch Control Circuit Diagnosis

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

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

21 Use an ohmmeter to check continuity between the
pressure switch (GRN/WHT) and the A/C thermostat
relay (GRN/WHT).
Was the circuit open? — Go to Step 22 Go to Step 23
22 Repair the open circuit between the pressure switch
and the A/C thermostat relay.
23 Check for damaged pin or terminal at F45 of the PCM.
Was a damaged pin or terminal found? — Go to Step 24 Go to Step 25
24 Repair the damaged pin or terminal.
25 Replace the PCM.
programmed. Refer to On-Vehicle Servicein
Powertrain Control Module Sensors for procedures.
And also refer to latest Service Bulletin.
26 1. Remove the A/C compressor relay.
3. Use a DVM to check voltage at both of the BRN
wires at the A/C compressor relay socket.
Is the voltage equal to the specified value? B+ Go to Step 28 Go to Step 27
27 Repair the faulty BRN wire between the A/C fuse and
the A/C compressor relay .
28 1. A/C compressor relay removed.
2. Engine idling.
3. A/C “ON.”
4. Blower “ON.”
5. Use a DVM to measure voltage between the
GRN/BLK wire at the A/C compressor relay socket
and battery±.
Did the DVM indicate the specified value? B+ Go to Step 32 Go to Step 29
29 Check for an open GRN/BLK wire between PCM
terminal F4 and the A/C compressor relay.
Was the wire open? — Go to Step 30 Go to Step 31
30 Repair the open GRN/BLK wire between the PCM and
the A/C compressor relay.
31 Check for a damaged pin or terminal at F4 of the PCM.
Was a damaged pin or a terminal found? — Go to Step 24 Go to Step 25

32 1. A/C compressor relay removed.
2. Connect a fused jumper at the A/C compressor
relay socket between either BRN wire and the
BRN/YEL wire.
3. Engine idling.
4. A/C “ON.”
5. Blower “ON.”
Did the compressor magnetic clutch engage? — Go to Step 33 Go to Step 34
33 Repair the A/C compressor relay.
34 Check for an open circuit between the A/C compressor
relay and the A/C clutch.
Was an open circuit found? — Go to Step 35 Go to Step 36
35 Repair the open circuit between the compressor Clutch
and the A/C compressor relay.
36 Service the compressor clutch or replace the
compressor due to a faulty internal overheat switch.
37 1. Remove the A/C compressor relay.
2. Idle the engine.
Is the compressor clutch still engaged when A/C is not
selected? — Go to Step 38 Go to Step 39
38 Repair the short to voltage between the A/C clutch and
A/C compressor relay.
39 1. Reinstall the A/C compressor relay.
2. Remove the A/C thermostat relay.
3. Engine idling.
Is the compressor clutch still engaged when A/C is not
selected? — Go to Step 40 Go to Step 42
40 Use a DVM to check for a short to ground between the
A/C compressor relay and F4 of the PCM.
Was a short detected? — Go to Step 41 Go to Step 25
41 Repair the short to ground between the PCM and A/C
compressor relay.
42 Repair the short to ground between the A/C thermostat
relay and the electronic thermostat.
Electronic Ignition System Diagnosis Fuel Injector Coil Test Procedure and
If the engine cranks but will not run or immediately stalls, Fuel Injector Balance Test Procedure
the Engine Cranks But Will Not Start chart must be used
to determine if the failure is the ignition system or the fuel
system. If DTC P0300 through P306, P0341, or P0336 is
set, the appropriate diagnostic trouble code chart must be
used for diagnosis.
If a misfire is being experienced with no DTC set, refer to
the Symptoms section for diagnosis.
EVAP Canister Purge Solenoid and

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

Emission Canister
D If the canister is cracked or damaged, replace the
canister.
D If fuel is leaking from the canister, replace the canister
and check hoses and hose routing. T32003
Test Description
Fuel Metering System Check
Number(s) below refer to the step number(s) on the
Some failures of the fuel metering system will result in an Diagnostic Chart:
“Engine Cranks But Will Not Run” symptom. If this
condition exists, refer to the Cranks But Will Not Run 2. Relieve the fuel pressure by connecting the J
chart. This chart will determine if the problem is caused 34730-1 Fuel Pressure Gauge to the fuel pressure
by the ignition system, the PCM, or the fuel pump connection on the fuel rail.
electrical circuit. CAUTION: In order to reduce the risk of fire and
Refer to Fuel System Electrical Test for the fuel system personal injury, wrap a shop towel around the fuel
wiring schematic. pressure connection. The towel will absorb any fuel
If there is a fuel delivery problem, refer to Fuel System leakage that occurs during the connection of the fuel
Diagnosis, which diagnoses the fuel injectors, the fuel pressure gauge. Place the towel in an approved
pressure regulator, and the fuel pump. If a malfunction container when the connection of the fuel pressure
occurs in the fuel metering system, it usually results in gauge is complete.
either a rich HO2S signal or a lean HO2S signal. This
condition is indicated by the HO2S voltage, which causes Place the fuel pressure gauge bleed hose in an
the PCM to change the fuel calculation (fuel injector pulse approved gasoline container.
width) based on the HO2S reading. Changes made to the With the ignition switch “OFF,” open the valve on the
fuel calculation will be indicated by a change in the long fuel pressure gauge.
term fuel trim values which can be monitored with a
3. Record the lowest voltage displayed by the DVM
Tech 2. Ideal long term fuel trim values are around 0%;
after the first second of the test. (During the first
for a lean HO2S signal, the PCM will add fuel, resulting in
second, voltage displayed by the DVM may be
a fuel trim value above 0%. Some variations in fuel trim
inaccurate due to the initial current surge.)
values are normal because all engines are not exactly the
same. If the evaporative emission canister purge is “ON,” Injector Specifications:
the fuel trim may be as low as –38%. If the fuel trim values
are greater than +23%, refer to DTC P0131, DTC P0151, Resistance Ohms Voltage Specification at
DTC P0171, and DTC 1171 for items which can cause a 10°C-35°C (50°F-95°F)
lean HO2S signal. 11.8 – 12.6 5.7 – 6.6
Fuel System Pressure Test

D The voltage displayed by the DVM should be within
A fuel system pressure test is part of several of the
the specified range.
diagnostic charts and symptom checks. To perform this
test, refer to Fuel Systems Diagnosis. D The voltage displayed by the DVM may increase
throughout the test as the fuel injector windings
warm and the resistance of the fuel injector windings
changes.
D An erratic voltage reading (large fluctuations in 7. The Fuel Injector Balance Test portion of this chart
voltage that do not stabilize) indicates an (Step 7 through Step 11) checks the mechanical
intermittent connection within the fuel injector. (fuel delivery) portion of the fuel injector. An engine
5. Injector Specifications: cool-down period of 10 minutes is necessary in
order to avoid irregular fuel pressure readings due
Highest Acceptable Acceptable Subtracted to “Hot Soak” fuel boiling.
Voltage Reading Value
Above/Below 35°C/10°C
(95°F/50°F)
9.5 Volts 0.6 Volts
Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure
(Steps 7-11)
R262001
CYLINDER 1 2 3 4 5 6
1st Reading (1) 296 kPa 296 kPa 296 kPa 296 kPa 296 kPa 296 kPa
(43 psi) (43 psi) (43 psi) (43 psi) (43 psi) (43 psi)
2nd Reading (2) 131 kPa 117 kPa 124 kPa 145 kPa 131 kPa 130 kPa
(19 psi) (17 psi) (18 psi) (21 psi) (19 psi) (19 psi)
Amount of Drop (1st 165 kPa 179 kPa 172 kPa 151 kPa 165 kPa 166 kPa
Reading–2nd Reading) (24 psi) (26 psi) (25 psi) (22 psi) (24 psi) (24 psi)
Av.drop = 166 kPa/24 psi ± OK Faulty, Rich OK Faulty, Lean OK OK
10 kPa/1.5 psi (Too Much (Too Little
= 156 – 176 kPa or Fuel Drop) Fuel Drop)
22.5 – 25.5 psi
NOTE: These figures are examples only.

(Steps 7-11)
performed? System
2 1. Turn the engine “OFF.”
NOTE: In order to prevent flooding of a single cylinder
and possible engine damage, relieve the fuel pressure
before performing the fuel injector coil test procedure.
2. Relieve the fuel pressure. Refer to Test Description
Number 2.
3. Connect the J 39021-5V Fuel Injector Tester to B+
and ground, and to the J 39021-90 Injector Switch
Box.
4. Connect the injector switch box to the grey fuel
injector harness connector located on the front of
the EVAP canister bracket.
5. Set the amperage supply selector switch on the fuel
injector tester to the “Coil Test” 0.5 amp position.
6. Connect the leads from the J 39200 Digital
Voltmeter (DVM) to the injector tester. Refer to the
illustrations associated with the test description.
7. Set the DVM to the tenths scale (0.0).
8. Observe the engine coolant temperature. 10°C (50°F)
Is the engine coolant temperature within the specified to 35°C
values? (95°F) Go to Step 3 Go to Step 5
3 1. Set injector switch box injector #1.
2. Press the “Push to Start Test” button on the fuel
injector tester.
3. Observe the voltage reading on the DVM.
IMPORTANT: The voltage reading may rise during the
test.
4. Record the lowest voltage observed after the first
second of the test.
5. Set the injector switch box to the next injector and
repeat steps 2, 3, and 4.
Did any fuel injector have an erratic voltage reading
(large fluctuations in voltage that did not stabilize) or a
voltage reading outside of the specified values? 5.7-6.6 V Go to Step 4 Go to Step 7
4 Replace the faulty fuel injector(s). Refer to Fuel
Injector.
(Steps 7-11) (Cont'd)
5 1. Set injector switch box injector #1.
2. Press the “Push to Start Test” button on the fuel
injector tester.
3. Observe the voltage reading on the DVM.
IMPORTANT: The voltage reading may rise during the
test.
4. Record the lowest voltage observed after the first
second of the test.
5. Set the injector switch box to the next injector and
repeat steps 2, 3, and 4.
Did any fuel injector have an erratic voltage reading
(large fluctuations in voltage that did not stabilize) or a
voltage reading above the specified value? 9.5 V Go to Step 4 Go to Step 6
6 1. Identify the highest voltage reading recorded (other
than those above 9.5 V).
2. Subtract the voltage reading of each injector from
the highest voltage selected in step 1. Repeat until
you have a subtracted value for each injector.
For any injector, is the subtracted Value in step 2
greater than the specified value? 0.6 V Go to Step 4 Go to Step 7
7 CAUTION: In order to reduce the risk of fire and
personal injury, wrap a shop towel around the
fuel pressure connection. The towel will absorb
any fuel leakage that occurs during the
connection of the fuel pressure gauge. Place the
towel in an approved container when the
connection of the fuel pressure gauge is
complete.
1. Connect the J 34730-1 Fuel Pressure Gauge to the
fuel pressure test port.
2. Energize the fuel pump using the Tech 2.
3. Place the bleed hose of the fuel pressure gauge into
an approved gasoline container.
4. Bleed the air out of the fuel pressure gauge.
5. With the fuel pump running, observe the reading on Go to Fuel
the fuel pressure gauge. 296-376 kPa System
Is the fuel pressure within the specified values? (43-55 psi) Go to Step 8 Diagnosis
8 Turn the fuel pump “OFF.” Go to Fuel
System
Does the fuel pressure remain constant?
— Go to Step 9 Diagnosis
(Steps 7-11) (Cont'd)
9 1. Connect the J 39021-5V Fuel Injector Tester and J
39021-90 Injector Switch Box the fuel injector
harness connector.
2. Set the amperage supply selector switch on the fuel
injector tester to the “Balance Test” 0.5–2.5 amp
position.
3. Using the Tech 2 turn the fuel pump “ON” then
“OFF” in order to pressurize the fuel system.
4. Record the fuel pressure indicated by the fuel
pressure gauge after the fuel pressure stabilizes.
This is the first pressure reading.
5. Energize the fuel injector by depressing the “Push
to Start Test” button on the fuel injector tester.
6. Record the fuel pressure indicated by the fuel
pressure gauge after the fuel pressure gauge
needle has stopped moving. This is the second
pressure reading.
7. Repeat steps 1 through 6 for each fuel injector.
8. Subtract the second pressure reading from the first
pressure reading for one fuel injector. The result is
the pressure drop value.
9. Obtain a pressure drop value for each fuel injector.
10.Add all of the individual pressure drop values. This
is the total pressure drop.
11. Divide the total pressure drop by the number of fuel
injectors. This is the average pressure drop.
Does any fuel injector have a pressure drop value that Go to OBD
is either higher than the average pressure drop or lower 10 kPa System
than the average pressure drop by the specified value? (1.5 psi) Go to Step 10 Check
10 Re-test any fuel injector that does not meet the
specification. Refer to the procedure in step 9.
NOTE: Do not repeat any portion of this test before
running the engine in order to prevent the engine from
flooding.
Does any fuel injector still have a pressure drop value
that is either higher than the average pressure drop or
lower than the average pressure drop by the specified 10 kPa Go to
value? (1.5 psi) Go to Step 11 Symptoms
11 Replace the faulty fuel injector(s). Refer to Fuel
Injector.
Powertrain Control Module (PCM) The PCM provides the following sensors with a 5–volt
reference and a sensor ground signal:
Diagnosis
1
To read and clear diagnostic trouble codes, use a Tech 2.
D The exhaust gas recirculating (EGR) pintle position
IMPORTANT: Use of a Tech 2 is recommended to clear
diagnostic trouble codes from the PCM memory. D sensor
Diagnostic trouble codes can also be cleared by turning D The manifold absolute pressure (MAP) sensor
the ignition “OFF” and disconnecting the battery power D The throttle position (TP) sensor 1
from the PCM for 30 seconds. Turning off the ignition and
D The acceleration position (AP) sensor 1
disconnecting the battery power from the PCM will cause
all diagnostic information in the PCM memory to be D The acceleration position (AP) sensor 3
cleared. Therefore, all the diagnostic tests will have to be D The Vapor Pressure Sensor
re-run. 2
Since the PCM can have a failure which may affect only
one circuit, following the diagnostic procedures in this D The Crank position (CKP) sensor
section will determine which circuit has a problem and D The Camshaft Position (CMP) Sensor
where it is. D The throttle position (TP) sensor 2
If a diagnostic chart indicates that the PCM connections D The acceleration position (AP) sensor 2
or the PCM is the cause of a problem, and the PCM is
The PCM monitors the separate feedback signals from
replaced, but this does not correct the problem, one of the
these sensors in order to determine their operating
following may be the reason:
status.
D There is a problem with the PCM terminal
connections. The terminals may have to be removed Diagnostic Aids
from the connector in order to check them properly.
D EEPROM program is not correct for the application. IMPORTANT: Be sure to inspect PCM and engine
Incorrect components or reprogramming the PCM grounds for being secure and clean.
with the wrong EEPROM program may cause a A short to voltage in one of the sensor input circuits may
malfunction and may or may not set a DTC. cause one or more of the following DTCs to be set:
D The problem is intermittent. This means that the D P0425
problem is not present at the time the system is being D P0108, P1106
checked. In this case, refer to the Symptoms portion D P0406
of the manual and make a careful physical inspection
of all component and wiring associated with the D P1120, P1515, P1221, P1516, P1635
affected system. D P1275, P1639, P1271, P1273
D There is a shorted solenoid, relay coil, or harness. D P1285, P1272, P1273
Solenoids and relays are turned “ON” and “OFF” by D P0336, P0337
the PCM using internal electronic switches called
D P0341, P0342
drivers. A shorted solenoid, relay coil, or harness will
not damage the PCM but will cause the solenoid or D P1220, P1515, P1221, P1515, P1516
relay to be inoperative. D P1280, P1271, P1272
IMPORTANT: If a sensor input circuit has been shorted
Multiple PCM Information Sensor to voltage, ensure that the sensor is not damaged. A
DTCs Set damaged sensor will continue to indicate a high or low
voltage after the affected circuit has been repaired. If the
Circuit Description sensor has been damaged, replace it.
An open in the sensor ground circuit between the PCM
The powertrain control module (PCM) monitors various
and the splice will cause one or more of the following
sensors to determine the engine operating conditions.
DTCs to be set:
The PCM controls fuel delivery, spark advance,
transmission operation, and emission control device D P0425
operation based on the sensor inputs. D P0108,P1106
The PCM provides a sensor ground to all of the sensors. D P0406
The PCM applies 5 volts through a pull–up resistor, and D P1120, P1515, P1221, P1516, P1635
determines the status of the following sensors by
D P1275, P1639, P1271, P1273
monitoring the voltage present between the 5–volt supply
and the resistor: D P1285, P1272, P1273
D The engine coolant temperature (ECT) sensor D P0336, P0337
D The intake air temperature (IAT) sensor D P0341, P0342
D The transmission fluid temperature (TFT) sensor D P1220, P1515, P1221, P1515, P1516
D P1280, P1271, P1272
A short to ground in the 5–volt reference A or B circuit will
cause one or more of the following DTCs to be set:
D P0453
D P0106, P0107, P1107
D P0401, P1404, P0405
D P1120, P1515, P1221, P1516, P1635
D P1275, P1639, P1271, P1273
D P1285, P1646, P1272, P1273
D P0336, P0337
D P0341, P0342
D P1220, P1515, P1221, P1515, P1516
D P1280, P1271, P1272
Check for the following conditions:
D Poor connection at PCM. Inspect the harness
connectors for backed–out terminals, improper
mating, broken locks, improperly formed or damage
terminals, and a poor terminal–to–wire connection.
D Damaged harness. Inspect the wiring harness for
damage. If the harness is not damaged, observe an
affected sensor fs displayed value on the Tech 2 with
the ignition “ON” and the engine “OFF” while you
move the connectors and the wiring harnesses
related to the following sensors:
D Vapor Pressure Sensor
D MAP Sensor
D EGR
D TPS1/TPS2
D APS1/APS2/APS3
D CKP/CMP
Multiple PCM Information Sensor DTCs Set

1 Was the “On-Board (OBD) System Check” performed? Go to OBD
System
2 1. Turn the ignition “OFF,” disconnect the PCM.
2. Turn the ignition “ON,” check the 5 volt reference 1
and 2 circuit for the following conditions:
D A poor connection at the PCM.
D An open between the PCM connector and the
splice.
D A short to ground.
D A short to voltage.
Is there an open or short? — Go to Step 3 Go to Step 4
3 Repair the open or short.
4 Check the sensor ground circuit for the following
conditions:
D A poor connection at the PCM or the affected
sensors.
D An open between the PCM connector and the
affected sensors.
Is there an open or a poor connection? — Go to Step 5 Go to Step 6
5 Repair the open or the poor connection.
Go to
P1635, P1639, P1646
applicable
7 Measure the resistance below the items:
D Between EGR sensor supply circuit and Vapor
Pressure Sensor supply circuit.
D Between MAP sensor supply circuit and Vapor
Pressure Sensor supply circuit.
D Between Vapor Pressure Sensor supply circuit
and PCM harness connector. (5Volt supply
circuit)
Does the resistance measure near the specified value? — Go to Step 9 Go to Step 8
8 Locate and repair the open circuit in the MAP or EGR or
Vapor Pressure sensor suppy circuit.
9 1. Disconnect the MAP , Vapor pressure sensor and
EGR connecter.
3. Measure the resistance below the items:
D MAP sensor GND circuit.
D EGR GND circuit.
D Vapor pressure sensor GND circuit.
Does the voltage resistance near the specified value? — Go to Step 11 Go to Step 10
Multiple PCM Information Sensor DTCs Set (Cont'd)

10 Locate and repair the short circuit in the MAP or EGR or
Vapor Pressure sensor signal or GND circuit.
11 Measure the resistance below the items:
D Between CKP sensor supply circuit and CMP
Sensor supply circuit.
D Between CKP Sensor supply circuit and PCM
harness connector. (5Volt supply circuit)
12 Locate and repair the open circuit in the CKP or CMP
sensor supply circuit.
13 1. Disconnect the CKP and CMP sensor connector.
3. Measure the voltage below the items:
D CKP sensor GND circuit and shield circuit.
D CMP sensor GND circuit and shield circuit.
14 Locate and repair the short circuit in the CKP or CMP
sensor signal or GND circuit.
15 Are more of the following items for DTCs stored? EGR, Go to
Vapor Pressure Sensor, MAP, CKP, CMP, TPS, APS applicable
16 Replace the PCM.
The replacement PCM must be programmed.
Refer to ON-Vehicle Service in Power Control Module
and Sensors for procedures.
if the latest software is released or not. And then Down
Load the LATEST PROGRMMED SOFTWARE to the
Go to OBD
replacement PCM.
System
Is the action complete? — Check —
Exhaust Gas Recirculation (EGR) DESIRED IDLE — Tech 2 Range 0-3187 RPM —
The idle speed that the PCM is commanding. The PCM
Diagnosis will compensate for various engine loads based on engine
An EGR flow check diagnosis of the linear EGR system is coolant temperature, to keep the engine at the desired
covered by DTC P0401. Pintle position error diagnosis is speed.
covered by DTC P0402, P0404, P1404, P0405, P0406. If
ECT — (Engine Coolant Temperature) Tech 2
EGR diagnostic trouble codes P0401 and/or P0402,
Range –40°C to 151°C (–40°F to 304°F) —
P0404, P1404, P0405, P0406 are encountered, refer to
The engine coolant temperature (ECT) is mounted in the
the DTC charts.
coolant stream and sends engine temperature
information to the PCM. The PCM applies 5 volts to the
Engine Tech 2 Data Definitions and ECT sensor circuit. The sensor is a thermistor which
Ranges changes internal resistance as temperature changes.
When the sensor is cold (high resistance), the PCM
A/C CLUTCH – Tech 2 Displays ON or OFF –
monitors a high signal voltage and interprets that as a cold
Indicates whether the PCM has commanded the A/C
engine. As the sensor warms (decreasing resistance),
clutch ON. Used in A/C system diagnostic.
the voltage signal will decrease and the PCM will interpret
A/C REQUEST — Tech 2 Displays YES or NO — the lower voltage as a warm engine.
Indicates the state of the A/C request input circuit from the
EGR DUTY CYCLE — Tech 2 Range 0%-100% —
HVAC controls. The PCM uses the A/C request signal to
Represents the EGR valve driver PWM signal from the
determine whether A/C compressor operation is being
PCM. A duty cycle of 0% indicates that no EGR flow is
requested.
being commanded; a 100% duty cycle indicates
AIR/FUEL RATIO — Tech 2 Range 0.0-25.5 — maximum EGR flow commanded.
Air/fuel ratio indicates the PCM commanded value. In
EGR FEEDBACK — Tech 2 Range 0.00-5.00 Volts —
closed loop, the air/fuel ratio should normally be
Indicates the EGR pintle position sensor signal voltage
displayed around “14.2-14.7.” A lower air/fuel ratio
being monitored by the PCM. A low voltage indicates a
indicates a richer commanded mixture, which may be
fully extended pintle (closed valve); a voltage near 5 volts
seen during power enrichment or TWC protection modes.
indicates a retracted pintle (open valve).
A higher air/fuel ratio indicates a leaner commanded
mixture. This can be seen during deceleration fuel mode. ENGINE LOAD — Tech 2 Range 0%-100% —
Engine load is calculated by the PCM from engine speed
AP1 —Tech 2 Range 0%-100% —
and MAF sensor readings. Engine load should increase
AP (accelerator pedal) angle is computed by the PCM
with an increase in RPM or air flow.
from the AP sensor voltage. AP angle should display “3%”
at idle and “85-89%” at wide open throttle. ENGINE RUN TIME — Tech 2 Range
00:00:00-99:99:99 Hrs:Min:Sec —
Indicates the time elapsed since the engine was started.
If the engine is stopped, engine run time will be reset to
from the AP sensor voltage. AP angle should display
00:00:00.
“85-89%” at idle and “11-15%” at wide open throttle.
ENGINE SPEED — Range 0-9999 RPM —
Engine speed is computed by the PCM from the 58X
reference input. It should remain close to desired idle
from the AP sensor voltage. AP angle should display
under various engine loads with engine idling.
“85-89%” at idle and “32-36%” at wide open throttle.
EVAP PURGE PWM — Tech 2 Range 0%-100% —
BAROMETRIC PRESSURE — Tech 2 Range 10-105
Represents the PCM commanded PWM duty cycle of the
kPa/0.00-5.00 Volts —
EVAP purge solenoid valve. “0%” displayed indicates no
The barometric pressure reading is determined from the
purge; “100%” displayed indicates full purge.
MAP sensor signal monitored during key up and wide
open throttle (WOT) conditions. The barometric pressure EVAP VACUUM SWITCH (Vent Valve) — Tech 2
is used to compensate for altitude differences and is Displays ON or OFF —
normally displayed around “61-104” depending on The EVAP purge vacuum switch is a normally closed
altitude and barometric pressure. switch positioned in the purge line between the canister
and the EVAP purge solenoid. The EVAP purge vacuum
CHECK TRANS LAMP — AUTO TRANSMISSION —
switch will open when vacuum increases to greater than
Indicates the need to check for a DTC with the Tech 2
5 inches of water in the purge line. The EVAP purge
when the lamp is flashing 0.2 seconds ON and 0.2
vacuum switch is used by the PCM to monitor EVAP
seconds OFF.
canister purge solenoid operation and purge system
DESIRED EGR POS. — Tech 2 Range 0%-100% — integrity. The EVAP purge vacuum switch should be
Represents the EGR pintle position that the PCM is closed to ground with no vacuum present (0% EVAP
commanding. purge PWM). With EVAP purge PWM at 25% or greater,
the EVAP purge vacuum switch should be open and
“PURGE” should be indicated.
FUEL PUMP — Tech 2 Displays ON or OFF — HO2S WARM UP TIME BANK 1, SEN. 1/BANK 1,
Indicates the PCM commanded state of the fuel pump SEN 2/BANK 2 SEN. 1/BANK 2 SEN. 2 — Tech 2
relay driver circuit. Range 00:00:00-99:99:99 HRS:MIN:SEC —
Indicates warm-up time for each HO2S. The HO2S
HO2S BANK 1, SEN. 1
warm-up time is used for the HO2S heater test. The PCM
— Tech 2 Range 0-1132 mV —
will run the heater test only after a cold start (determined
Represents the fuel control exhaust oxygen sensor
by engine coolant and intake air temperature at the time
output voltage. Should fluctuate constantly within a range
of start-up) and only once during an ignition cycle. When
between 10 mV (lean exhaust) and 1000 mV (rich
the engine is started the PCM will monitor the HO2S
exhaust) while operating in closed loop.
voltage. When the HO2S voltage indicates a sufficiently
HO2S BANK 1, SEN. 2 active sensor, the PCM looks at how much time has
— Tech 2 Range 0-1000mV — elapsed since start-up. If the PCM determines that tool
Monitors the exhaust oxygen sensor output voltage. The much time was required for the HO2S to become active,
PCM monitors the operating efficiency of catalytic a DTC will set. If the engine was warm when started,
converter by comparing the output voltages of sensor 1 HO2S warm-up will the display “00:00:00”.
and sensor 2 in this bank. If the catalytic converter is
IAT (INTAKE AIR TEMPERATURE) — Tech 2 Range
operating efficiently, the output voltage of sensor 1 will
–40°C to 151°C (–40°F to 304°F) —
give a greater fluctuation than that of sensor 2. If the
The PCM converts the resistance of the intake air
PCM detects an abnormal level of voltage fluctuation
temperature sensor to degrees. Intake air temperature
from sensor 2, a DTC P0420 will be set, indicating that the
(IAT) is used by the PCM to adjust fuel delivery and spark
catalytic converter for this bank is no longer operating
timing according to incoming air density.
efficiently.
IGNITION 1 — Tech 2 Range 0-25.5 Volts —
HO2S BANK2, SEN. 1 —Tech 2 Range 0-1132 mV—
This represents the system voltage measured by the
Represents the fuel control exhaust oxygen sensor
PCM at its ignition feed.
output voltage. Should fluctuate constantly within a range
between 10mV (lean exhaust) and 1000 mV (rich INJ. PULSE BANK 1/INJ. PULSE BANK 2 — Tech 2
exhaust) while operating in closed loop. Range 0-1000 msec. —
Indicates the amount of time the PCM is commanding
HO2S BANK 2, SEN. 2—Tech 2 Range 0-1000 mV—
each injector “ON” during each engine cycle. A longer
Monitors the exhaust oxygen sensor output voltage. The
injector pulse width will cause more fuel to be delivered.
PCM monitors the operating efficiency of catalytic
Injector pulse width should increase with increased
converter by comparing the output voltages of sensor 1
engine load.
and sensor 2 in this bank. If the catalytic converter is
operating efficiently, the output voltage of sensor 1 will LONG TERM FUEL TRIM BANK 1/BANK 2 —
have a greater fluctuation than that of sensor 2. If the The long term fuel trim is derived from the short term fuel
PCM detects an abnormal level of voltage fluctuation trim values and represents a long term correction of fuel
from sensor 2, a DTC P0430 will be set, indicating that the delivery for the bank in question. A value of 0% indicates
catalytic converter for this bank is no longer operating that fuel delivery requires no compensation to maintain
efficiently. the PCM commanded air/fuel ratio. A negative value
significantly below 0% indicates that the fuel system is
HO2S BANK 1, SEN. 1—Tech 2 Displays NOT
rich and fuel delivery is being reduced (decreased injector
READY or READY—
pulse width). A positive value significantly greater than
Indicates the status of the exhaust oxygen sensor. The
0% indicates that a lean condition exists and the PCM is
Tech 2 will indicate that the exhaust oxygen sensor is
compensating by adding fuel (increased injector pulse
ready when the PCM detects a fluctuating HO2S voltage
width). Because long term fuel trim tends to follow short
sufficient to allow closed loop operation. This will not
term fuel trim, a value in the negative range due to
occur unless the exhaust oxygen sensor is warmed up.
canister purge at idle should not be considered unusual.
HO2S BANK 2, SEN. 1 — Tech 2 Displays NOT Fuel trim values at maximum authority may indicate an
READY or READY — excessively rich or lean system.
Indicates the status of the exhaust oxygen sensor. The
Fuel System STATUS — Tech 2 Displays OPEN or
Tech 2 will indicate that the exhaust oxygen sensor is
CLOSED —
ready when the PCM detects a fluctuating HO2S voltage
“CLOSED” indicates that the PCM is controlling fuel
sufficient to allow closed loop operation. This will not
delivery according to oxygen sensor voltage. In “OPEN”
occur unless the exhaust oxygen sensor is warmed up.
the PCM ignores the oxygen sensor voltage and bases
the amount of fuel to be delivered on TP sensor, engine
coolant, and MAF sensor inputs only.
MAF — Tech 2 Range 0.0-512 gm/s —
MAF (mass air flow) is the MAF input frequency
converted to grams of air per second. This indicates the
amount of air entering the engine.
MAP START-UP IAT — Tech 2 Range –40°C to 151°C
— Tech 2 Range 10-105 kPa (0.00-4.97 Volts) — (–40°F to 304°F) —
The manifold absolute pressure (MAP) sensor measures Indicates the intake air temperature at the time that the
the change in the intake manifold pressure from engine vehicle was started. Used by the HO2S diagnostic to
load, EGR flow, and speed changes. As intake manifold determine if the last start-up was a cold start.
pressure increases, intake vacuum decreases, resulting
TOTAL MISFIRE CURRENT COUNT — Tech 2
in a higher MAP sensor voltage and kPa reading. The
Range 0-255 —
MAP sensor signal is used to monitor intake manifold
Indicates the total number of cylinder firing events that
pressure changes during the EGR flow test, to update the
were detected as being misfires during the last 200
BARO reading, and as an enabling factor for several of
crankshaft revolution sample period.
the diagnostics.
TP — Tech 2 Range 0%-100% —
MIL — Tech 2 Displays ON or OFF —
TP (throttle position) angle is computed by the PCM from
Indicates the PCM commanded state of the malfunction
the TP sensor voltage. TP angle should display “8-13%”
indicator lamp.
at idle and “87-97%” at wide open throttle.
MISFIRE CUR. CYL. #1 /#2 /#3 /#4 / #5 / #6 — Tech 2
CATALYST PROTECTION MODE — Tech 2 Displays
Range 0-255 Counts —
YES or NO —
The misfire current counters increase at a rate according
“YES” displayed indicates that the PCM has detected
to the number of the possible misfires being detected on
conditions appropriate to operate in TWC protection
each cylinder. The counters may normally display some
mode. The PCM will decrease the air/fuel ratio to a value
activity, but the activity should be nearly equal for all the
that depends on mass air flow (higher mass air flow =
cylinders.
lower air/fuel ratio).
MISFIRE CUR. CYL. #1 /#2 /#3 /#4 / #5 / #6 — Tech 2
UPSHIFT LAMP (MANUAL TRANSMISSION)
VEHICLE SPEED — Tech 2 Range 0-255 km/h
The misfire history counters display the relative level of
(0-155 mph) —
misfire that has been detected on each cylinder. The
The vehicle speed sensor signal is converted into km/h
misfire history counters will not update or show any
and mph for display.
activity until a misfire DTC (P0300) has become active.
WEAK CYLINDER — Tech 2 Displays Cylinder
MISFIRE FAILURES SINCE FIRST FAIL — Tech 2
Number —
This indicates that the PCM has detected crankshaft
Indicates the number of 200 crankshaft revolution sample
speed variations that indicate 2% or more cylinder firing
periods during which the level of misfire was sufficiently
events are misfires.
high to report a fail.
MISFIRE PASSES SINCE FIRST FAIL — Tech 2 Typical Scan Data Values
Indicates the number of 200 crankshaft revolution sample Use the Typical Scan Data Values Table only after the
periods during which the level of misfire was sufficiently On-Board Diagnostic System Check has been
low to report a pass. completed, no DTC(s) were noted, and you have
determined that the on-board diagnostics are functioning
POWER ENRICHMENT — Tech 2 Displays ACTIVE properly. Tech 2 values from a properly-running engine
or INACTIVE — may be used for comparison with the engine you are
“ACTIVE” displayed indicates that the PCM has detected diagnosing. The typical scan data values represent
conditions appropriate to operate in power enrichment values that would be seen on a normally-running engine.
mode. The PCM will command power enrichment mode
NOTE: A Tech 2 that displays faulty data should not be
when a large increase in throttle position and load is
used, and the problem should be reported to the Tech 2
detected. While in power enrichment mode, the PCM will
manufacturer. Use of a faulty Tech 2 can result in
increase the amount of fuel delivered by entering open
misdiagnosis and unnecessary replacement of parts.
loop and increasing the injector pulse width. This is done
to prevent a possible sag or hesitation from occurring Only the parameters listed below are referred to in this
during acceleration. service manual for use in diagnosis. For further
information on using the Tech 2 to diagnose the PCM and
SPARK — Tech 2 Range –64° to 64° — related sensors, refer to the applicable reference section
Displays the amount of spark advance being commanded listed below. If all values are within the typical range
by the PCM on the IC circuit. described below, refer to the Symptoms section for
START-UP ECT — Tech 2 Range –40°C to 151°C diagnosis.
(–40°F to 304°F) —
Indicates the engine coolant temperature at the time that Test Conditions
the vehicle was started. Used by the HO2S diagnostic to Engine running, lower radiator hose hot, transmission in
determine if the last start-up was a cold start. park or neutral, closed loop, accessaries off, brake not
applied and air conditioning off.
3.5L V-6 Engine (Automatic and Manual Transmission)
Tech 2 Data List Units Typical Data Typical Data Refer To

Parameter Displayed Values (IDLE) Values
(2500 RPM)
A/C Clutch Engine On/Off Off Off General Description and
Relay Operation, A/C Clutch
Circuit Operation
A/C Request Engine Yes/No No No General Description and
Operation, A/C Request
Signal
Air/Fuel Ratio Engine Ratio: _ to 14.7 14.7 General Description and
1 Operation, Fuel System
Metering Purpose
APP Sensor1 Engine Percent 11–13 35–40 General Description and
Operation
Operation
Operation
Barometric Engine kPa 61-104 (depends 61-104 (depends General Description and
Pressure on altitude and on altitude and Operation
barometric) barometric)
Brake Light Engine Open Open 0V Open 0V Refer to Section 5
Switch 0V/Closed
12V
Check Trans Engine On/Off Off Off 4L30-E Automatic
Lamp (Auto Transmission Diagnosis
Trans)
Cruise Main Engine Active/Inac Inactive Inactive Refer to Section 10
Switch tive
Cruise Set Engine Active/Inac Inactive Inactive Refer to Section 10
Switch tive
Cruise Cancel Engine Active/Inac Inactive Inactive Refer to Section 10
Switch tive
Cruise Resume Engine Active/Inac Inactive Inactive Refer to Section 10
Switch tive
Decel Fuel Engine Active/Inac Inactive Inactive General Description and
Cutoff tive Operation, Deceleration
Mode
Desired EGR Engine Percent 0% 0% General Description and
Position Operation, EGR Pintle
Position Sensor
Desired Idle Engine RPM 750 800 General Description and
Speed Operation
ECT (Engine Engine Degrees C, 80-100°C 80-100°C General Description and
Coolant Temp) Degrees F (176-212°F) (176-212°F) Operation, Engine Coolant
Temperature (ECT) Sensor
EGR Closed Engine Steps 20-40 20-40 General Description and
Pintle Position Operation, EGR Pintle
Position Sensor
EGR Duty Cycle Engine Percent 0% 0% General Description and
Operation, Linear EGR
Operation and Results of
Incorrect Operation

(2500 RPM)
EGR Feedback Engine Volts 0.45-0.80 0.45-0.80 —
EGR Engine Percent 0% 0%
—
Normalized
Engine Load Engine Percent 2.0% - 5.5% 8.0% - 16.0% General Description and
Operation, Mass Air Flow
(MAF) Sensor
Time From Start Engine Sec Varies. Resets at Varies. Resets at
each engine each engine —
start. start.
Engine Speed Engine RPM Within –50 to Actual engine
+100 of “Desired speed —
Idle”
EVAP Purge Engine Percent 0% 0% Diagnosis, EVAP Emission
Solenoid Canister Purge Valve
Check
EVAP Vent Engine On/Off Off Off Diagnosis, EVAP Canister
Valve Purge Solenoid and EVAP
Vacuum Switch and Visual
Check; DTCs: P1441,
P1442
Fuel System Engine Open Closed Loop Closed Loop General Description
Status Loop/Close
d Loop
Fuel Level Engine Percent — — Engine Fuel
Fuel Level Engine Volts Engine Fuel
— —
Sensor
Fuel Tank Engine Volts 1.02 – 1.86 1.02 – 2.57 General Description and
Pressure Operation
O eration
Sensor in. H2O — —
Fuel Pump Engine On/Off On On Engine Fuel

HO2S Bank 1 O2 Sensor Millivolts 50-950 changing 50-950, always General Description and
Sen.1 (millivolts) Data quickly changing quickly Operation, Fuel control
HO2S
HO2S Bank 1 O2 Sensor Millivolts 200-700 250-650 General Description and
Sen.2 (millivolts) Data changing slowly changing slowly Operation, Fuel Metering
(Auto Trans) System
HO2S Bank 1 O2 Sensor Millivolts 50-950 changing 50-950 changing General Description and
Sen.2 (millivolts) Data quickly quickly Operation, Fuel Metering
(Manual Trans) System
Sen.3 (millivolts) Data changing slowly changing slowly Operation, Catalyst
(Manual Trans) Monitor Heated Oxygen
Sensor (Manual Trans)
HO2S Bank 2 O2 Sensor Millivolts 50-950 changing 50-950 changing General Description and
Sen.1 (millivolts) Data quickly quickly Operation, Fuel Control
HO2S
Sen.2 (millivolts) Data changing slowly changing slowly Operation, Fuel Metering
(Auto trans) System

(2500 RPM)
HO2S Bank 1 O2 Sensor Ready Ready Ready General Description and
Sen.1 Data Yes/No Yes Yes Operation, Fuel Control
(ready/not HO2S; DTC: P0135
ready)
HO2S Bank 2 O2 Sensor Ready Ready Ready General Description and
Sen.1 Data Yes/No Yes Yes Operation, Fuel Control
(ready/not HO2S
ready)
HO2S Warm-Up O2 Sensor Seconds 25-45 25-45 General Description and
Time Bank 1 Data Operation, Fuel Control
Sen.1 HO2S
Sen.2 HO2S
Sen.1 HO2S
Time Bank 2 Data Operation, Catalyst
Sen.2 Monitor Heated Oxygen
Sensor (Auto Trans)
IAT (Intake Air Engine Degrees C, 0-100°C, 0-80°C, depends General Description and
Temp) Degrees F depends on on underhood Operation, Intake Air
underhood Temperature (IAT) Sensor
Illumination Engine Closed Closed 0V Closed 0V Refer to Section 8
Switch 0V/Open
12V
Ignition Voltage Engine Volts 12.8-14.1 12.8-14.1 General Description and
Operation, Electronic
Ignition System
Inj. Pulse Bank Engine Millisecond 2.0-4.0 2.5-4.0 General Description, Fuel
1 s Metering, Fuel Injector
Inj. Pulse Bank Engine Millisecond 2.0-4.0 2.5-4.0 General Description, Fuel
2 s Metering, Fuel Injector
Knock Present Engine No/Yes No No General Description and
ION Sensing Module
Knock Signal Engine Percent 1∼4 1∼4 General Description and
ION Sensing Module
Knock Sensor Engine °CA 0 0 General Description and
Retard ION Sensing Module
Knock Counter Engine Counts — — General Description
Long Term FT Misfire Counts 100 to 150 100 to 150 Diagnosis, Fuel Trim
Bank 1 (Long and counts, –22% to counts, –22% to System Monitor; DTCs:
Term Fuel Trim) Percent +17% +17% P0171, P0172
Long Term FT Misfire Counts 100 to 150 100 to 150 Diagnosis, Fuel Trim
Bank 2 (Long and counts, –22% to counts, –22% to System Monitor; DTCs:
Term Fuel Trim) Percent +17% +17% P0171
MAF (Mass Air Engine Grams per 2.85-6.65 9.5-16.5 General Description and
Flow) second Operation, MAF; DTCs:
P101, P0102, P0103

(2500 RPM)
MAP kPa Engine Kilopascals 23-40 19-32 General Description and
(Manifold Operation, Manifold
Absolute Absolute Pressure (MAP)
Pressure) Volts 0.65-1.32 0.46-1.10 Sensor; DTCs: P0106,
P0107, P0108
MIL Engine On/Off Off Off On-Board Diagnostic
System Check
Misfire Cur. Cyl Misfire Counts 0-2 0-2 DTC P0300
#1
#2
#3
#4
#5
#6
Misfire Hist. Cyl Misfire Counts 0 0 DTC P0300
#1
#2
#3
#4
#5
#6
Misfire Failures Misfire Counts 0 0 DTC P0300
Since First Fail
Misfire Passes Misfire Counts 0 0 DTC P0300
Since First Fail
PNP Engine P-N / P-N P-N 4L30-E Automatic
(Park/Neutral R-D-3-2-L Transmission Diagnosis
Position)
Power Engine NO/YES NO NO General Description and
Enrichment Operation, Acceleration
Mode
PSP Switch Engine Normal/Hi Normal Pressure Normal Pressure Refer to 2A Section
(Power Steering
Pressure)
Spark Engine Degrees 15-22 34-44 General Description and
(Advance) Before Top Operation, Electronic
Dead Ignition System
Center
Start-Up ECT Engine Degrees C, Depends on Depends on General Description and
(Engine Coolant Degrees F engine coolant engine coolant Operation, Engine Coolant
Temp) temperature at temperature at Temperature (ECT) Sensor
time of start-up time of start-up

(2500 RPM)
Start-Up IAT Engine Degrees C, Depends on Depends on General Description and
(Intake Air Degrees F intake air intake air Operation, Intake Air
Temp) temperature at temperature at Temperature (IAT) Sensor
time of start-up time of start-up
TCC Cruise Engine Active/Inac Active Active Refer to Section 10
Brake Switch tive
Total Misfire Misfire Counts 0-5 0-5 DTC P0300
Current Count
TP Sensor 1 Engine Percent 3–13 12–21 General Description and
(Throttle Operation, Throttle
Position Sensor Position (TP) Sensor
1)
TP Sensor 2 Engine Percent 87–97 79–88 General Description and
(Throttle Operation, Throttle
Position Sensor Position (TP) Sensor
2)
Throttle at Idle Engine No/Yes Yes No General Description and
Operation, Throttle
Position (TP) Sensor
Upshift Lamp Engine On/Off Off Off Manual Transmission
(manual trans)
Vehicle Speed Engine MPH / 0 0 4L30-E Automatic
km/h Transmission Diagnosis
Weak Cylinder Misfire Cylinder # — — DTC P0300
No Malfunction Indicator Lamp (MIL)
D06RY00127
Circuit Description Test Description

The “Check Engine” lamp (MIL) should always be Number(s) below refer to the step number(s) on the
illuminated and steady with the ignition “ON” and the Diagnostic Chart.
engine stopped. Ignition feed voltage is supplied to the 2. A “No MIL” condition accompanied by a no-start
MIL bulb through the meter fuse. The powertrain control condition suggests a faulty PCM ignition feed or
module (PCM) turns the MIL “ON” by grounding the MIL battery feed circuit.
driver circuit. 9. Using a test light connected to B+, probe each of the
PCM ground terminals to ensure that a good ground
Diagnostic Aids is present. Refer to PCM Terminal End View for
An intermittent MIL may be cased by a poor connection, terminal locations of the PCM ground circuits.
rubbed-through wire insulation, or a wire broken inside 12.In this step, temporarily substitute a known good
the insulation. Check for the following items: relay for the PCM relay. The horn relay is nearby,
D Inspect the PCM harness and connections for and it can be verified as “good” simply by honking
improper mating, broken locks, improperly formed or the horn. Replace the horn relay after completing
damaged terminals, poor terminal-to-wire this step.
connection, and damaged harness. 17.This vehicle is equipped with a PCM which utilizes
D If the engine runs OK, check for a faulty light bulb, an an electrically erasable programmable read only
open in the MIL driver circuit, or an open in the memory (EEPROM). When the PCM is replaced,
instrument cluster ignition feed. the new PCM must be programmed. Refer to PCM
D If the engine cranks but will not run, check for an open Replacement and Programming Procedures
PCM ignition or battery feed, or a poor PCM to engine Powertrain Control Module (PCM) and Sensors.
ground.
No Malfunction Indicator Lamp (MIL)

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

15 Locate and repair the short to ground in the PCM
ignition feed circuit or PCM battery feed circuit.
16 Locate and repair the short to ground in the ignition
feed circuit to the instrument cluster, and replace the
fuse.
17 Replace the PCM.
programmed. Refer to PCM in ON-Vehicle Service for
procedures.
18 Check the MIL driver circuit for a poor connection at the Go to
instrument panel connector. Instrument
Panel in
Electrical
— Verify repair Diagnosis
Malfunction Indicator Lamp (MIL) “ON” Steady
D06RY00127
Circuit description Test Description

The malfunction indicator lamp (MIL) should always be Number(s) below refer to the step number(s) on the
illuminated and steady with ignition “ON” and the engine Diagnostic Chart.
stopped. Ignition feed voltage is supplied directly to the 2. If the MIL does not remain “ON” when the PCM is
MIL indicator. The powertrain control module (PCM) disconnected, the MIL driver wiring is not faulty.
turns the MIL “ON” by grounding the MIL driver circuit. 3. If the MIL driver circuit is OK, the instrument panel
The MIL should not remain “ON” with the engine running cluster is faulty.
and no DTC(s) set. A steady MIL with the engine running
6. This vehicle is equipped with a PCM which utilizes
and no DTC(s) suggests a short to ground in the MIL
an electrically erasable programmable read only
driver circuit.
memory (EEPROM). When the PCM is replaced,
the new PCM must be programmed. Refer to PCM
Diagnostic Aids Replacement and Programming Procedures in
An intermittent may be caused by a poor connection, Powertrain Control Module (PCM) and Sensors.
rubbed-through wire insulation, or a wire broken inside
the insulation. Check for the following items:
D Poor connection or damaged harness – Inspect the
PCM harness and connectors for improper mating,
broken locks, improperly formed or damaged
terminals, poor terminal-to-wire connection, and
damaged harness.
Malfunction Indicator Lamp (MIL) “ON” Steady

1 Was the “On-Board diagnostic (OBD) System Check” Go to OBD
performed? System
2 1. Ignition “OFF,” disconnect PCM.
2. Ignition “ON,” observe the MIL (Service Engine
Soon lamp).
Is the MIL “ON?” — Go to Step 3 Go to Step 5
3 1. Ignition “OFF,” disconnect the instrument panel
cluster.
2. Check the MIL driver circuit between the PCM and
the instrument panel cluster for a short to ground.
Go to OBD
3. If a problem is found, repair as necessary. System
Was the MIL driver circuit shorted to ground? — Check Go to Step 4
4 Replace the instrument panel cluster. Go to OBD
System
Is the action complete?
— Check —
5 1. Ignition “OFF,” reconnect the PCM.
2. Ignition “ON,” reprogram the EEPROM. Refer to
On-Vehicle Service in Powertrain Control Module
3. Using the Tech 2 output controls function, select
MIL dash lamp control and command the MIL Go to OBD
“OFF.” (Refer to the Miscellaneous test) System
Did the MIL turn “OFF?” — Check Go to Step 6
6 Replace the PCM.
programmed. Refer to On-Vehicle Service in
Powertrain Control Module and Sensors for
procedures.
Go to OBD
System
No Reduced Power Lamp (RPL)
D06RY00127

The Reduced Power lamp (RPL) should always be Number(s) below refer to the step number(s) on the
illuminated and steady with the ignition “ON” and the Diagnostic Chart.
engine stopped. Ignition feed voltage is supplied to the 2. A “ No RPL”condition accompanied by a no - start
RPL bulb through the meter fuse. The powertrain control condition suggests a faulty PCM ignition feed or
module (PCM) turns the RPL “ON” by grounding the RPL battery feed circuit.
driver circuit. 9. Using a test light connected to B + , probe each of
the PCM ground terminals to ensure that a good
Diagnostic Aids ground is present. Refer toPCM Terminal End View
An intermittent RPL may be cased by a poor connection, for terminal locations of the PCM ground circuits.
rubbed - through wire insulation, or a wire broken inside 12. In this step, temporarily substitute a known good
the insulation. Check for the following items: relay for the PCM relay. The horn relay is nearby,
D Inspect the PCM harness and connections for and it can be verified as “good” simply by honking
improper mating, broken locks, improperly formed or the horn. Replace the horn relay after completing
damaged terminals, poor terminal-to-wire this step.
connection, and damaged harness.
D If the engine runs OK, check for a faulty light bulb, an an electrically erasable programmable read only
open in the MIL driver circuit, or an open in the memory (EEPROM). When the PCM is replaced,
instrument cluster ignition feed. the new PCM must be programmed. Refer to PCM
D If the engine cranks but will not run, check for an open Replacement and Programming Procedures in
PCM ignition or battery feed, or a poor PCM to engine Powertrain Control Module (PCM) and Sensors.
ground.
No Reduced Power Lamp (RPL)

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

15 Locate and repair the short to ground in the PCM
ignition feed circuit or PCM battery feed circuit.
16 Locate and repair the short to ground in the ignition
feed circuit to the instrument cluster, and replace
thefuse.
17 Replace the PCM.
programmed.
if the latest software is released or not.
And then Down Load the LATEST PROGRMMED
18 Check the RPL driver circuit for a poor connection at Go to
the instrument panel connector. Instrument
Panel in
Electrical
— Verify repair Diagnosis
Reduced Power Lamp (RPL) “ON” Steady
D06RY00127

The Reduced Power lamp (RPL) should always be Number(s) below refer to the step number(s) on the
illuminated and steady with ignition “ON” and the engine Diagnostic Chart.
stopped. Ignition feed voltage is supplied directly to the 2. If the RPL does not remain “ON” when the PCM is
RPL indicator. The powertrain control module (PCM) disconnected, the RPL driver wiring is not faulty.
turns the RPL “ON” by grounding the RPL driver circuit. 3. If the RPL driver circuit is OK, the instrument panel
The RPL should not remain “ON” with the engine running cluster is faulty.
and no DTC(s) set. A steady RPL with the engine running
and no DTC(s) suggests a short to ground in the RPL 6. This vehicle is equipped with a PCM which utilizes
driver circuit. an electrically erasable programmable read only
memory (EEPROM). When the PCM is replaced,
Diagnostic Aids the new PCM must be programmed. Refer toPCM
Replacement and Programming Procedures in
An intermittent RPL may be cased by a poor connection, Powertrain Control Module (PCM) and Sensors.
D Poor connection or damaged harness-Inspect the
damaged harness.
Reduced Power Lamp (RPL) “ON” Steady

1 Was the “ On - Board Diagnostic (OBD) System Check” Go to OBD
performed? System
2 1. Ignition “OFF,” disconnect PCM.
2. Ignition “ON,” observe the RPL (Reduced Power
Lamp).
Is the RPL “ ON?” — Go to Step 3 Go to Step 5
3 1. Ignition “OFF,” disconnect the instrument panel
cluster.
2. Check the RPL driver circuit between the PCM and
the instrument panel cluster for a short to ground.
Go to OBD
3. If a problem is found, repair as necessary. System
Was the RPL driver circuit shorted to ground? — Check Go to Step 4
4 Replace the instrument panel cluster. Go to OBD
System
— Check —
5 1. Ignition “OFF,” reconnect the PCM.
2. Ignition “ON,” reprogram the EEPROM. Refer to On
- Vehicle Service in Powertrain Control Module and
Sensors for procedures.
3. Using the Tech 2 output controls function, select
RPL dash lamp control and command the RPL Go to OBD
“OFF.” (Refer tothe Miscellaneous test) System
Did the MIL turn “OFF”? — Check Go to Step 6
6 Replace the PCM.
programmed.
Go to OBD
SOFTWARE to the replasement PCM. System
Engine Cranks But Will Not Run
D06RY00150
D06RY00042
The electronic Ignition system uses a coil -at-plug method Number(s) below refer to the step number(s) on the
of spark distribution. In this type of ignition system, the Diagnostic Chart.
powertrain control module (PCM) triggers the correct 5. An obvious cause of low fuel pressure would be an
driver outside the Ignition Current Sense System (ICSS), empty fuel tank.
which then triggers the correct ignition coil based on the 6. The engine will easily start and run if a few injectors
58X signal received from the crankshaft position sensor are disabled. It is not necessary to test all injectors
(CKP). The spark plug connected to the coil fires when at this time since this step is only a test to verify that
the ICSS opens the ground circuit for the coil’s primary all of the injectors have not been disabled by fuel
circuit. contamination.
During crank, the PCM monitors the CKP 58X signal. The
7. A blinking test light verifies that the PCM monitoring
CKP signal is used to determine which cylinder will fire
the 58X crankshaft reference signal and is capable
first. After the CKP 58X signal has been processed by the
of activating the injectors. If there is an open or
PCM, it will command all six injectors to allow a priming shorted driver circuit, DTCs 201 – 206 and a misfire
shot of fuel for all the cylinders. After the priming, the DTC 300 – 306 should be set.
injectors are left “OFF” during the next six 58X reference
pulses from the CKP. This allows each cylinder a chance 19. By using a spark tester, each ignition coil’s ability to
to use the fuel from the priming shot. During this waiting produce 25,000 volts is verified.
been received by the PCM. The CMP signal allows the 25. If there is an open or shorted driver circuit, DTCs
PCM to operate the injectors sequentially based on 201 – 206 and a misfire DTC 301 – 306 should be
camshaft position. If the camshaft position signal is not set. All six injector driver circuits can be checked at
present at start - up, the PCM will begin sequential fuel one time without removing the intake manifold if a J
delivery with a 1 -in-6 chance that fuel delivery is correct. 39021 – 95 test light is available. This is the
The engine will run without a CMP signal, but will set a alternative procedure:
DTC code. D With the ignition “OFF”, disconnect the gray
connector located at the rear of the air filter, attached
Diagnostic Aids to a bracket on the purge canister.
An intermittent problem may be caused by a poor D Connect test light J 39021 – 95 to the connector. Do
connection, rubbed - through wire insulation or a wire any of the light constantly illuminate or fail to blink
broken inside the insulation. Check for the following when the engine is cranked? If so, repair the short or
items: open circuit, or replace the PCM if indicated.
D Poor connection or damaged harness-Inspect the This procedure only tests the driver circuit as far as the
PCM harness and connectors for improper mating, test connection, so step 31 is added to test the circuit all
broken locks, improperly formed or damaged the way to the injector.
damaged harness.
D Faulty engine coolant temperature sensor-Using a
Tech 2, compare engine coolant temperature with
intake air temperature on a completely cool engine.
Engine coolant temperature should be within 10 ° C of
intake air temperature. If not, replace the ECT sensor.
Engine Cranks But Will Not Run

1 Was the “On-Board Diagnostic (OBD) System Go to OBD
Check”performed? System
2 Check the ignition coil fuse, the engine fuse, and the
PCM fuse.
Was a fuse blown? — Go to Step 3 Go to Step 4
3 Check for a short to ground and replace the fuse.
Engine Cranks But Will Not Run (Cont'd)

4 1. Ignition “OFF”, install a fuel pressure gauge at the
test fitting on the fuel supply line in the engine
compartment. (Use a shop cloth to absorb any fuel
leakage while making the connection.)
2. Ignition “ON,” observe the fuel pressure.
Is the fuel pressure within the specified values, and 285 - 375 kPa
does it hold steady? (43 – 55 psi) Go to Step 6 Go to Step 5
5 Is any fuel pressure indicated? Go to Fuel Go to Fuel
System System
— Electrical Test Diagnosis
6 Install the switch box J 39021–2 at the injector test
connector and activate an injector.
Did the fuel pressure drop when the injector was
activated? — Go to Step 7 Go to Step 18
7 Install an injector test light at the #2 cylinder injector
harness connector.
Does the light blink when the engine is cranked? — Go to Step 8 Go to Step 24
8 1. Ignition “ OFF.”
2. Disconnect the 11-pin connector at the ION sensing
module.
3. With a test light to B + , probe each of the 6 exposed
ION sensing module pins, one at a time, while the
engine is cranked. (Use the gray narrow Metri - Pak
 flexible female connector from the J - 35616 kit to
make the pin accessible.)
Does the light flash at each pin when the engine is
cranked? — Go to Step 12 Go to Step 9
9 1. Remove the 4-pin connector at the ION sensing
module.
2. Ignition “ ON.”
3. Use a test light at the harness connector to verify
that the module is being supplied with B + and
ground.
10 Repair the open ignition feed circuit or ground circuit to
the ION sensing module.
11 Repair the ION sensing module.
12 1. Reconnect the ION sensing module 11-pin
connector.
2. Remove the electrical connector from each coil.
3. With a test light to B+, probe each of the coil
connectors at the wire which runs to the ION
sensing module.
Does the light flash at each coil connector when the
engine is cranked? — Go to Step 14 Go to Step 13
13 Check for an open circuit between the coil and ION
sensing module.

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

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

31 1. At the injector (male) side of the gray connector
mentioned in step 25, connect an ohmmeter
between the ignition pin and one of the driver circuit
pins.
2. Check for continuity in the circuit.
3. Repeat for each injector circuit. The readings
should be approximately equal to the specified
value for injector resistance.
Was a problem found? 12.5 W Verify repair Go to Step 8
32 Repair the ignition feed circuit.
33 Replace the PCM.
programmed.
Check to see if the latest software is released or not.
34 1. Raise the vehicle and disconnect the CKP sensor
harness.
3. With a test light to ground, probe the harness
ignition feed terminal.
Did the light illuminate? — Go to Step 36 Go to Step 35
35 Check the ignition feed wire between the sensor
andthe PCM for a short to ground or open circuit.
2. At the CKP harness connector, connect a test light
between the ignition and ground terminals.
37 Check the sensor ground circuit for an open or short to
voltage.
38 Check the signal circuit between the sensor and the
PCM for a short to ground, short to voltage, or an open.
39 Replace the CKP position sensor.
Fuel System Electrical Test
D06RY00150
Circuit Description Fuel Pressure Relief Procedure
When the ignition switch is first turned “ON,” the 1. Remove the fuel cap.
powertrain control module (PCM) energizes the fuel
2. Remove the fuel pump relay from the underhood
pump relay which applies power to the in-tank fuel pump. relay center.
The fuel pump relay will remain “ON” as long as the
engine is running or cranking and the PCM is receiving 3. Start the engine and allow it to stall.
58X crankshaft position pulses. If no 58X crankshaft 4. Crank the engine for an additional 3 seconds.
position pulses are present, the PCM de-energizes the
fuel pump relay within 2 seconds after the ignition is Fuel Gauge Installation
turned “ON” or the engine is stopped. 1. Remove the shoulder fitting cap.
The fuel pump delivers fuel to the fuel rail and injectors, 2. Install fuel gauge J 34730-1 to the fuel feed line
then to the fuel pressure regulator. The fuel pressure located in front of and above the right side valve train
regulator controls fuel pressure by allowing excess fuel to cover .
be returned to the fuel tank. With the engine stopped and
3. Reinstall the fuel pump relay.
ignition “ON,” the fuel pump can be turned “ON” by using a
command by the Tech 2.
Diagnostic Aids
An intermittent may be caused by a poor connection,
damaged harness.
Test Description
Diagnostic Chart.
2. If the fuel pump is operating but incorrect pressure is
noted, the fuel pump wiring is OK and the “Fuel
System Pressure Test” chart should be used for
diagnosis.
CAUTION: To reduce the risk of fire and personal

injury:
D It is necessary to relieve fuel system pressure
before connecting a fuel pressure gauge. Refer to
Fuel Pressure Relief Procedure, below.
D A small amount of fuel may be released when
disconnecting the fuel lines. Cover fuel line
fittings with a shop towel before disconnecting, to
catch any fuel that may leak out. Place the towel in
an approved container when the procedure is
completed.
Fuel System Electrical Test

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

11 Replace the PCM.
procedures.
12 1. Reconnect the fuel pump relay.
2. Disconnect the fuel pump electrical connector at the
fuel tank.
fuel pump feed wire (harness side).
4. Command the fuel pump “ON” with a Tech 2.
Did the light illuminate for 2 seconds? — Go to Step 15 Go to Step 13
13 1. Honk the horn to verify that the horn relay is
functioning.
2. Substitute the horn relay for the fuel pump relay.
3. Leave the test light connected as in step 12.
4. Command the fuel pump “ON” with the Tech 2.
Did the test light illuminate for 2 seconds when the fuel
pump was commanded “ON?” — Go to Step 17 Go to Step 14
14 1. Re-connect the horn relay in its proper location.
2. Check for a short circuit, blown fuse or open circuit
between the relay and the fuel tank.
15 1. With the fuel pump electrical connector at the fuel
tank disconnected, connect a test light between the
feed wire and the ground wire (harness side).
2. Command the fuel pump “ON” with a Tech 2.
Did the test light illuminate for 2 seconds? — Go to Step 18 Go to Step 16
16 Repair the open circuit in the fuel pump ground wire.
17 1. Re-connect the horn relay in its proper location.
2. Replace the fuel pump relay.
18 Replace the fuel pump.
Electric Throttle Control (ETC) System Check
D06RY00179
D The powertrain control module (PCM) controls Number(s) below refer to the step number(s) on the
engine speed by adjusting the position of the throttle Diagnostic Chart:
control valve (DC motor). The throttle motor is a DC 2. Visually/physically inspect for the following throttle
motor driven by one coil. The PCM applies current to valve conditions.
the DC motor coil in PWM (%) to adjust the throttle
3. Visually/physically inspect for the following
valve into a passage in the throttle body to allow air
acceleration pedal conditions.
flow. This method allows highly accurate control of
engine speed and quick response to changes in 5. Check the following circuits for throttle valve and DC
engine load. moter. Check the following TP sensor resistance
D The acceleration position (AP1) sensor circuit and DC motor.
provides a voltage signal relative to acceleration 7. Check the following circuits for acceleration pedal.
pedal angle. Check the following AP sensor resistance.
The acceleration pedal angle will vary about 13% at 10. Following DTC: Software detect Error for ETC
idle position to about 87% at wide open system.
throttle(WOT).
11. Following DTC: Software detect Error for ETC
APS signal is used to determine which DC motor will system.
adjust throttle position.
After the APS signal has been processed by the
PCM, it will command DC motor to allow movement
of throttle position.
Diagnostic Aids
D An intermittent may be caused by a poor connection,
rubbed-through wire insulation or a wire broken inside
the insulation. Check for poor connections or a
damaged harness. Inspect the PCM harness and
connector for improper mating, broken locks,
improperly formed or damaged terminals, poor
terminal-to-wire connection, and damaged harness.
D Throttle body – Check for objects blocking the DC
motor or throttle bore, excessive deposits in the ETC
passage and on the valve spring, and excessive
deposits in the throttle bore and on the throttle valve
plate.
D Acceleration pedal – Check for objects blocking the
AP sensor or pedal arm with spring, and excessive
deposits in the acceleration pedal arm and on the
acceleration pedal.
Electric Throttle Control (ETC) System Check

performed? System
2 Visually/physically inspect for the following conditions:
D Throttle body tampering.
D Restricted intake throttle system. Check for a
possible collapsed air intake duct, restricted air
filter element, or foreign objects blocking the air
intake system.
D Throttle body: Check for objects blocking the
throttle passage or throttle bore, excessive
deposits in the throttle passage and on the throttle
valve, and excessive deposits in the throttle bore
and on the throttle plate.
D Throttle body with lever: When check for objects
to send round the throttle spring lever that lever is
smooth movement by less than 9 l·bm{1.0 N·m},
and spring lever has not excessive play.
D Throttle function: Check for the throttle function. Refer to
When ignition switch “ON” that throttle lever is appropriate
smooth operated by step on the acceleration section for
pedal. on-vehicle
Did any of the above require a repair? — service Go to Step 3
D Acceleration pedal tampering.
D Acceleration pedal : Check for objects blocking
the spring or pedal arm.
D Acceleration pedal : For check for objects to move
Refer to
the acceleration pedal that pedal is smooth
appropriate
movement, and acceleration pedal arm has not
section for
excessive play.
on-vehicle
Did any of the above require a repair? — service Go to Step 4
4 1. Check for a poor connection at the throttle body
harness connector.
2. Check for a poor connection at the acceleration
position sensor harness connector.
3. If a problem is found, replace faulty terminals as
necessary.
5 Check the following circuits for an open, short to
voltage, short to ground, or poor connection at the
PCM:
D Throttle position sensor 1 circuit.
D Throttle DC motor circuit. Vcc–GND
D Throttle position sensor resistance. 1–7kW
D Throttle DC motor resistance. SIG–GND
change
If a problem is found, repair as necessary. resistance
Was a problem found? 0.3–100W Verify repair Go to Step 6
Electric Throttle Control (ETC) System Check (Cont'd)

6 1. Install the Tech 2 Idle
2. Ignition “ON” but not engine run. AP1 = 11–13%
3. Chech the valve for APS and TPS. AP2 = 87–88%
AP3 = 87–88%
Was the prblem found? TP1 = 3–13%
TP2 = 87–97%
WOT
AP1 = 85–89%
AP2 = 11–15%
AP3 = 32–36%
TP1 = 87–97%
TP2 = 3–13% Go to Step 10 Go to Step 7
7 Replace the throttle valve.
PCM:
D Acceleration position sensor 1 circuit.
D Acceleration position sensor 3 circuit. Vcc–GND
D Acceleration position sensor resistance. 4–6kW
SIG–GND
If a problem is found, repair as necessary.
change
Was a problem found? resistance Verify repair Go to Step 9
9 Replace the acceleration position sensor.
Is the action complete? — Go to Step 10 –
Go to
P1125, P1290, P1295, P1299
applicable
Go to
P1514, P1515, P1516, P1523, P1271, P1272, P1273
applicable
12 Replace the PCM.
procedures.
Fuel System Diagnosis
140RW020
Legend (8) Fuel Rail Left

(1) Fuel Filler Cap (9) Left Bank
(2) Fuel Tank (10) Fuel Pressure Control Valve
(3) Rollover Valve (11) Common Chamber
(4) Fuel Pump and Sender Assembly (12) Duty Solenoid Valve
(5) Fuel Filter (13) Throttle Valve
(6) Fuel Rail Right (14) Canister
(7) Right Bank (15) Evap Shut Off Valve

When the ignition switch is turned “ON,” the powertrain Number(s) below refer to the step number(s) on the
control module (PCM) will turn “ON” the in-tank fuel Diagnostic Chart.
pump. The in-tank fuel pump will remain “ON” as long as 2. Connect the fuel pressure gauge to the fuel feed line
the engine is cranking or running and the PCM is receiving as shown in the fuel system illustration. Wrap a
58X crankshaft position pulses. If there are no 58X shop towel around the fuel pressure connection in
crankshaft position pulses, the PCM will turn the in-tank order to absorb any fuel leakage that may occur
fuel pump “OFF” 2 seconds after the ignition switch is when installing the fuel pressure gauge. With the
turned “ON” or 2 seconds after the engine stops running. ignition switch “ON” and the fuel pump running, the
The in-tank fuel pump is an electric pump within an fuel pressure indicated by the fuel pressure gauge
integral reservoir. The in-tank fuel pump supplies fuel should be 333-376 kPa (48-55 psi). This pressure
through an in-line fuel filter to the fuel rail assembly. The is controlled by the amount of pressure the spring
fuel pump is designed to provide fuel at a pressure above inside the fuel pressure regulator can provide.
the pressure needed by the fuel injectors. A fuel pressure 3. A fuel system that cannot maintain a constant fuel
regulator, attached to the fuel rail, keeps the fuel available pressure has a leak in one or more of the following
to the fuel injectors at a regulated pressure. Unused fuel areas:
is returned to the fuel tank by a separate fuel return line. D The fuel pump check valve.
D The fuel pump flex line.
D The valve or valve seat within the fuel pressure 20.This test determines if the high fuel pressure is due
regulator. to a restricted fuel return line or if the high fuel
D The fuel injector(s). pressure is due to a faulty fuel pressure regulator.
4. Fuel pressure that drops off during acceleration, 21.A lean condition may result from fuel pressure
cruise, or hard cornering may case a lean condition. below 333 kPa (48 psi). A lean condition may
A lean condition can cause a loss of power, surging, cause a DTC P0131 or a DTC P0171 to set.
or misfire. A lean condition can be diagnosed using Driveability conditions associated with lean
a Tech 2. If an extremely lean condition occurs, the conditions can include hard starting (when the
oxygen sensor(s) will stop toggling. The oxygen engine is cold ), hesitation, poor driveability, lack of
sensor output voltage(s) will drop below 500 mV. power, surging , and misfiring.
Also, the fuel injector pulse width will increase. 22.Restricting the fuel return line causes the fuel
IMPORTANT: Make sure the fuel system is not pressure to rise above the regulated fuel pressure.
operating in the “Fuel Cut-Off Mode.” Command the fuel pump “ON” with the Tech 2. The
fuel pressure should rise above 376 kPa (55 psi) as
When the engine is at idle, the manifold pressure is the fuel return line becomes partially closed.
low (high vacuum). This low pressure (high vacuum)
is applied to the fuel pressure regulator diaphragm. NOTE: Do not allow the fuel pressure to exceed 414 kPa
The low pressure (high vacuum) will offset the (60 psi). Fuel pressure in excess of 414 kPa (60 psi) may
pressure being applied to the fuel pressure regulator damage the fuel pressure regulator.
diaphragm by the spring inside the fuel pressure
regulator. When this happens, the result is lower fuel CAUTION: To reduce the risk of fire and personal
pressure. The fuel pressure at idle will vary slightly as injury:
the barometric pressure changes, but the fuel
pressure at idle should always be less than the fuel D It is necessary to relieve fuel system pressure
pressure noted in step 2 with the engine “OFF.” before connecting a fuel pressure gauge. Refer to
Fuel Pressure Relief Procedure, below.
16.Check the spark plug associated with a particular D A small amount of fuel may be released when
fuel injector for fouling or saturation in order to disconnecting the fuel lines. Cover fuel line
determine if that particular fuel injector is leaking. If fittings with a shop towel before disconnecting, to
checking the spark plug associated with a particular catch any fuel that may leak out. Place the towel in
fuel injector for fouling or saturation does not an approved container when the procedure is
determine that a particular fuel injector is leaking, completed.
use the following procedure:
D Remove the fuel rail, but leave the fuel lines and Fuel Pressure Relief Procedure
injectors connected to the fuel rail. Refer to Fuel Rail
Assembly in On-Vehicle Service. 1. Remove the fuel cap.
D Lift the fuel rail just enough to leave the fuel injector 2. Remove the fuel pump relay from the underhood
nozzles in the fuel injector ports. relay center.
3. Start the engine and allow it to stall.
CAUTION: In order to reduce the risk of fire and 4. Crank the engine for an additional 3 seconds.
personal injury that may result from fuel spraying on
the engine, verify that the fuel rail is positioned over
the fuel injector ports and verify that the fuel injector
Fuel Gauge Installation
retaining clips are intact. 1. Remove the shoulder fitting cap.
D Pressurize the fuel system by connecting a 10 amp 2. Install fuel gauge J 34730-1 to the fuel feed line
fused jumper between B+ and the fuel pump relay located in front of and above the right side valve train
connector. cover.
D Visually and physically inspect the fuel injector 3. Reinstall the fuel pump relay.
nozzles for leaks.
17.A rich condition may result from the fuel pressure
being above 376 kPa (55 psi). A rich condition may
cause a DTC P0132 or a DTC P0172 to set.
Driveability conditions associated with rich
conditions can include hard starting (followed by
black smoke) and a strong sulfur smell in the
exhaust.
Fuel System Diagnosis

performed? System
2 1. Turn the ignition “OFF.”
2. Turn the air conditioning system “OFF.”
3. Relieve fuel system pressure and install the fuel
pressure gauge.
4. Turn the ignition “ON.”
NOTE: The fuel pump will run for approximately 2
seconds. Use the Tech 2 to command the fuel pump
“ON”.
5. Observe the fuel pressure indicated by the fuel
pressure gauge with the fuel pump running. 290-376 kPa
Is the fuel pressure within the specified limits? (42-55 psi) Go to Step 3 Go to Step 17
3 NOTE: The fuel pressure will drop when the fuel pump
stops running, then it should stabilize and remain
constant.
Does the fuel pressure indicated by the fuel pressure
gauge remain constant? — Go to Step 4 Go to Step 12
4 1. When the vehicle is at normal operation
temperature, turn the ignition “ON” to build fuel
pressure and observe the measurement on the
gauge.
2. Start the engine and observe the fuel pressure
gauge.
Did the reading drop by the amount specified after the 21-105 kPa
engine was started? (3-15 psi) Go to Step 5 Go to Step 9
5 Is fuel pressure dropping off during acceleration, Check for
cruise, or hard cornering? — Go to Step 6 improper fuel
6 Visually and physically inspect the following items for a
restriction:
D The in-pipe fuel filter.
D The fuel feed line.
Was a restriction found? — Verify repair Go to Step 7
7 Remove the fuel tank and visually and physically
inspect the following items:
D The fuel pump strainer for a restriction.
D The fuel line for a leak.
D Verify that the correct fuel pump is in the vehicle.
Was a problem found in any of these areas? — Verify repair Go to Step 8
8 Replace the fuel pump.
9 1. Disconnect the vacuum hose from the fuel pressure
regulator.
2. With the engine idling, apply 12-14 inches of
vacuum to the fuel pressure regulator.
Does the fuel pressure indicated by the fuel pressure 21-105 kPa
gauge drop by the amount specified? (3-15 psi) Go to Step 10 Go to Step 11
Fuel System Diagnosis (Cont'd)

10 Locate and repair the loss of vacuum to the fuel
pressure regulator.
11 Replace the fuel pressure regulator.
12 1. Run the fuel pump with the Tech 2.
2. After pressure has built up, turn off the pump and
clamp the supply hose shut with suitable locking
pliers which will not damage the hose.
13 Visually inspect the fuel supply line and repair any
leaks.
14 Remove the fuel tank and inspect for leaky hose or
in-tank fuel line.
15 1. If the pliers are still clamped to the fuel supply hose,
remove the locking pliers.
2. With suitable locking pliers, which will not damage
the hose, clamp the fuel return line to prevent fuel
from returning to the fuel tank.
3. Run the fuel pump with the Tech 2.
4. After pressure has built up, remove power to the
pump.
16 Locate and replace any leaking fuel injector(s).
17 Is the fuel pressure indicated by the fuel pressure 376 kPa
gauge above the specified limit? (55 psi) Go to Step 18 Go to Step 21
18 1. Relieve the fuel pressure. Refer to the Fuel
Pressure Relief.
2. Disconnect the fuel return line from the fuel rail.
3. Attach a length of flexible hose to the fuel rail return
outlet passage.
4. Place the open end of the flexible hose into an
approved gasoline container.
5. Run the fuel pump with the Tech 2.
6. Observe the fuel pressure indicated by the fuel
pressure gauge with the fuel pump running. 290-376 kPa
Is the fuel pressure within the specified limits? (42-55 psi) Go to Step 19 Go to Step 20
19 Locate and correct the restriction in the fuel return line.
20 Visually and physically inspect the fuel rail outlet
passages for a restriction.
Was a restriction found? — Verify repair Go to Step 11
Fuel System Diagnosis (Cont'd)

21 Is the fuel pressure indicated by the fuel pressure
gauge above the specified value? 0 kPa (0 psi) Go to Step 22 Go to Step 23
22 1. Command the fuel pump “ON” with the Tech 2.
2. Using suitable pliers which will not damage the fuel
hose, gradually apply pressure with the pliers to
pinch the flexible fuel return hose closed.
CAUTION: Do not let the fuel pressure exceed
376 kPa
the second specified value.
(55 psi)
Does the fuel pressure indicated by the fuel pressure 414 kPa
gauge rise above the first specified value? (60 psi) Go to Step 11 Go to Step 7
23 1. Command the fuel pump “ON” with the Tech 2.
2. Remove the fuel filler cap and listen for the sound of
the fuel pump running. Go to Fuel
System
3. Turn the pump off. Electrical Test
Was the fuel pump running? — Go to Step 7 Chart
Exhaust Gas Recirculation (EGR) System Check
060RY00167
Circuit Description Diagnostic Aids

A properly operation exhaust gas recirculation (EGR) The EGR valve chart is a check of the EGR system. An
system will directly affect the air/fuel requirements of the EGR pintle constantly in the closed position could cause
engine. Since the exhaust gas introduced into the air/fuel detonation and high emissions of NOx. It could also result
mixture is an inert gas (contains very little or no oxygen), in high long term fuel trim values in the open throttle cell,
less fuel is required to maintain a correct air/fuel ratio. but not in the closed throttle cell. An EGR pintle
Introducing exhaust gas into the combustion chamber constantly in the open position would cause a rough idle.
lowers combustion temperatures and reduces the Also, an EGR mounted incorrectly (rotated 180°) could
formation of oxides of nitrogen (NOx) in the exhaust gas. cause rough idle. Check for the following items:
Lower combustion temperatures also prevent detonation. D EGR passages – Check for restricted or blocked EGR
If the EGR pintle were to stay closed, the inert exhaust passages.
gas would be replaced with air and the air/fuel mixture D Manifold absolute pressure sensor – A manifold
would be leaner. The powertrain control module (PCM) absolute pressure sensor may shift in calibration
would compensate for the lean condition by adding fuel, enough to affect fuel delivery. Refer to Manifold
resulting in higher long term fuel trim values. Absolute Pressure Output Check.
Exhaust Gas Recirculation (EGR) System Check

1 Check the EGR valve for looseness.
Is the EGR valve Loose? — Go to Step 2 Go to Step 3
2 Tighten the EGR valve.
3 1. Place the transmission selector in Park or Neutral.
2. Start the engine and idle until warm. EGR system
3. Using a Tech 2, command EGR “50% ON.” working
properly. No
problem
Does the engine idle rough and lose RPMs? — found. Go to Step 4
4 1. Engine “OFF.”
3. Using a test light to ground, check the EGR harness
between the EGR valve and the ignition feed.
Does the test light illuminate? — Go to Step 6 Go to Step 5
5 Repair the EGR harness ignition feed.
Was the problem corrected? — Verify repair Go to Step 6
6 1. Remove the EGR valve.
2. Visually and physically inspect the EGR valve
pintle, valve passages and adapter for excessive
deposits, obstructions or any restrictions.
Does the EGR valve have excessive deposits,
obstructions or any restrictions? — Go to Step 7 Go to Step 8
7 Clean or replace EGR system components as
necessary.
Was the problem corrected? — Verify repair Go to Step 8
8 1. Ground the EGR valve metal case to battery (–).
2. Using a Tech 2, command EGR “ON” and observe
the EGR valve pintle for movement.
Does the EGR valve pintle move according to Go to DTC
command? — Go to Step 9 P1406 chart
9 1. Remove the EGR inlet and outlet pipes from the
intake and exhaust manifolds.
2. Visually and physically inspect manifold EGR ports
and EGR inlet and outlet pipes for blockage or
restriction caused by excessive deposits or other EGR system
damage. working
Do the manifold EGR ports or inlet and outlet pipes properly. No
have excessive deposits, obstructions, or any problem
restrictions? — Go to Step 10 found.
10 Clean or replace EGR system components as
necessary.
Manifold Absolute Pressure (MAP) Output Check
D06RY00165

The manifold absolute pressure (MAP) sensor measures IMPORTANT: Be sure to used the same diagnostic test
the changes in the intake MAP which result from engine equipment for all measurements.
load (intake manifold vacuum) and engine speed The number(s) below refer to the step number(s) on the
changes; and converts these into a voltage output. The Diagnostic Chart.
powertrain control module (PCM) sends a 5-volt
2. Applying 34 kPa (10 Hg) vacuum to the MAP sensor
reference voltage to the MAP sensor. As the MAP should cause the voltage to be 1.5-2.1 volts less
changes, the output voltage of the sensor also changes. than the voltage at step 1. Upon applying vacuum
By monitoring the the sensor output voltage, the PCM to the sensor, the change in voltage should be
knows the MAP. A lower pressure (low voltage) output instantaneous. A slow voltage change indicates a
voltage will be about 1-2 volts at idle. Higher pressure faulty sensor.
(high voltage) output voltage will be about 4-4.8 volts at
3. Check the vacuum hose to the sensor for leaking or
wide open throttle. The MAP sensor is also used, under
restriction, Be sure that no other vacuum devices
certain conditions, to measure barometric pressure,
are connected to the MAP hose.
allowing the PCM to make adjustments for different
altitudes. The PCM uses the MAP sensor to diagnose IMPORTANT: Make sure the electrical connector
proper operation of the EGR system, in addition to other remains securely fastened.
functions. 4. Disconnect the sensor from the bracket. Twist the
sensor with your hand to check for an intermittent
connection. Output changes greater than 0.10 volt
indicate a bad sensor.
Manifold Absolute Pressure (MAP) Output Check

1 1. Turn the ignition “OFF”and leave it “OFF” for 15
seconds.
2. Ignition “ON.” Don’t crank engine.
3. The Tech 2 should indicate a manifold absolute
pressure (MAP) sensor voltage.
4. Compare this scan reading to scan reading of a
known good vehicle obtained using the exact same
procedure as in Steps 1-4.
Is the voltage reading the same +/–0.40 volt? — Go to Step 2 Go to Step 5
2 1. Disconnect the vacuum hose at the MAP sensor
and plug the hose.
2. Connect a hand vacuum pump to the MAP sensor.
3. Start the engine.
4. Apply 34 kPa (10 Hg) of vacuum and note the
voltage change.
Is the voltage change 1.5-2.1 volts less than Step 1? — Go to Step 3 Go to Step 4
3 Check the sensor cover for leakage or restriction.
Does the hose supply vacuum to the MAP sensor only? — Go to Step 5 Go to Step 4
4 Repair the hose to block.
5 Check the sensor connection.
Is the sensor connection good? — Go to Step 6 Go to Step 7
6 Refer to On-Vehicle Service, MAP Sensor.
7 Repair the poor connection.
Evaporative (EVAP) Emissions Canister Purge Valve Check
D06RY00128

Canister purge is controlled by a solenoid valve that D Make a visual check of vacuum hoses.
allows manifold vacuum to purge the canister. The D Check the throttle body for possible cracked.
powertrain control module (PCM) supplies a ground to
D Check the malfunction indicator lamp for a possible
energize the solenoid valve (purge “ON”). The EVAP
mechanical problem.
purge solenoid control is turned “ON” and “OFF” several
times a second. The duty cycle (pulse width or “ON” time)
Test Description
is determined by engine operating conditions including
load, throttle position, coolant temperature and ambient The number(s) below refer to the step number(s) on the
temperature. The duty cycle is calculated by the PCM Diagnostic Chart.
and the purge solenoid is enabled when the appropriate 1. Check to see if the solenoid is open or closed. The
conditions have been met: solenoid is normally de-energized in this step, so it
should be closed.
D The engine run time after start is more than 60
seconds. 2. This step checks to determine if the solenoid was
D The engine coolant temperature is above 30°C open due to an electrical circuit problem or a
(86°F). defective solenoid.
D The fuel control system is operating in the closed-loop 3. This should normally energize the solenoid, opening
mode. the valve and allowing the vacuum to drop (purge
“ON”).
Evaporative (EVAP) Emissions Canister Purge Valve Check

3. At the throttle body, disconnect the hose that goes
to the pump solenoid.
4. Using a hand vacuum pump with an attached
vacuum gauge J 23738-A, apply vacuum (10” Hg or
34 kPa) to the solenoid.
Does the solenoid hold the vacuum? — Go to Step 3 Go to Step 2
2 1. Disconnect the solenoid electrical connector.
2. As in Step 1, apply vacuum (10” Hg or 34 kPa) to the
solenoid.
Does the solenoid hold the vacuum? — Go to Step 4 Go to Step 7
3 1. At the throttle body, put a cap over the vacuum port
where the hose was disconnected for testing. This
is to prevent a vacuum leak when the engine is
started.
2. Ignition “OFF.”
3. Install the Tech 2.
4. Apply vacuum to the purge solenoid with the hand
vacuum pump.
5. Start the engine, run at 2500 RPM.
6. Using the Tech 2, select Powertrain, 3.5–V6 6VE1,
F3: Misc. Tests, F2: EVAP Purge, F0: EVAP Purge.
(Refer to the Misellaneous Test.)
7. Turn the purge solenoid “ON.”
Did the vacuum drop when the purge was turned on? — Go to Step 8 Go to Step 9
4 Check for a short to ground in the RED/BLU wire.
Is there a short? — Go to Step 5 Go to Step 6
5 Repair the short to ground.
6 Replace the PCM.
programmed. Refer to On-Vehicle Servicein
procedures.
7 Replace the faulty purge solenoid. Refer to On-Vehicle
Service, EVAP Canister Purge Solenoid.
Evaporative (EVAP) Emissions Canister Purge Valve Check (Cont'd)

2. At the throttle body, install a vacuum gauge where
the hose from the purge solenoid was disconnected
for testing.
4. Stabilize the engine speed at about 2500 RPM. No problem
found in the
5. Momentarily snap the throttle open and let it return EVAP
to idle. emission
Is there approximately 10” Hg (34 kPa) of vacuum canister Refer to
available at the EVAP emission canister purge purge valve Diagnostic
solenoid? — check Aids
9 1. Disconnect the solenoid electrical connector.
2. Connect a test lamp between the harness
terminals.
Does the test lamp light? — Go to Step 7 Go to Step 10
10 Probe terminal A and terminal B with a test lamp to
ground.
Does the test lamp light on both terminals? — Go to Step 11 Go to Step 12
11 Repair the short to voltage in the RED/BLUE wire.
12 Does on of the terminals light the test lamp? — Go to Step 13 Go to Step 14
13 Check for an open in the RED/BLU wire between the
purge solenoid and the PCM.
14 Repair the open in the BLK/YEL wire.
15 Repair the open in the RED/BLU wire.
Upshift Lamp System Check (Manual Transmission Only)
060RY00127
Circuit Description Inspect the PCM harness and connector for proper
The shift lamp indicates the best transmission shift point mating, broken locks, improperly formed or damaged
for maximum fuel economy. terminals, poor terminal-to-wire connection and
The lamp is controlled by the Power Train Control Module damaged harness.
(PCM) and is turned “ON” by grounding the BLK wire.
The PCM is used information from the following inputs to
Test Description
control the upshift lamp. 1. This should not turn “ON” the up-shift lamp. If the
D Engine Coolant temperature (ECT) Sensor lamp is “ON”, there is a short to ground in BLK or a
fault PCM.
D Throttle Position Sensor
2. This checks the upshift lamp circuit up to the PCM
D Vehicle Speed Sensor connector.
D Engine Speed If the up-shift lamp illuminates, then the PCM
The PCM uses the measured RPM and the vehicle speed connector is faulty or PCM does not have the ability
to calculate what gear the vehicle is in. to ground the circuit.
It’s this calculation that determines when the upshift lamp
should be turned “ON”.
Diagnostic Aids
rubbed-through wire insulation. Check for poor
connections or a damaged harness.
Up-Shift Lamp System Check

1 1. Verify the customer complaints in accordance with
mentioned below: Go to the adequate Step Chart
first.
D At the 1st gear position, the lamp doesn’t
illuminate: Go to Step Chart
D At the 3rd gear position, the lamp doesn’t
illuminate: Go to Step Chart
D Upshift Lamp doesn’t illuminate always.
2. Ignition “ON”, engine “OFF”.
3. Using the Tech 2, check to see if the upshift lamp
turn “ON” or “OFF”.
Does the upshift lamp stay “OFF”? — Go to Step 2 Go to Step 12
2 Check for an open of 15A Turn Backup Fuse.
Was a problem found? Go to Step 4
Refer to Sec-
— Go to Step 3 tion 8
3 Replace the fuse.
Is the action complete? Verify Repair — —
4 Check for an burned out the Upshift Lamp.
5 Replace the Upshift Lamp.
6 1. Check for an Clutch Switch operation and the fixing
condition.
2. Check for an open or short of clutch switch.
3. Check for an open or short of WHT/GRN wiring
harness between Turn Backup Fuse and Clutch
Switch.
Up-Shift Lamp System Check (Cont'd)

7 1. Replace the Clutch Switch. Or,
2. Repair for an open or short of WHT/GRN wiring
harness.
8 1. Check for an open or short of 1-2 Transmission
Switch.
2. Check for an open or short of 3-4 Transmission
Switch.
3. Check for an open or short of GRN wiring harness
between Clutch Switch and Transmission
Switches.
9 1. Replace the applicable Transmission Switch. or,
2. Repair for an open or short of GRN wiring harness.
10 1. Check for an open or short in the Alarm and Relay
Control Unit.
2. Check for an open of BLU/ORN wiring harness
between Transmission Switches and Alarm Relay
Control Unit.
11 1. Replace the Alarm and Relay Control Unit. Or,
2. Repair for an open of BLU/ORN wiring harness
between Alarm and Relay Control Unit and PCM
connector.
Is the action complete? Verify Repair — Go to Step 15
12 1. Ignition “OFF”.
2. Disconnect the PCM connectors.
3. Shift the gear to 1st or 4th gear position.
4. Turn ignition “ON”, but don’t start the engine.
Does the Upshift Lamp Stay “ON”? — Go to Step 13 Go to Step 15
13 Check for an short to ground of YEL/GRN wiring
harness between Alarm and PCM connector.
14 Repair for an open YEL/GRN wiring harness.
15 Replace the PCM.
programmed refer to ON-Vehicle Service in Power
Train Control Module and Sensor for procedure.
Is the action complete? — — —
PCM Diagnostic Trouble Codes

The following table lists the diagnostic trouble codes
supported by this vehicle application. If any DTCs not
listed here are displayed by a Tech 2, the Tech 2 data may
be faulty; notify the Tech 2 manufacturer of any DTCs
displayed that are not included in the following table.
PCM Diagnostic Trouble Codes
DTC Description Type Illuminate Illuminate

MIL RPL
(Check (Reduced
Enigne Power
Lamp) Lamp)
P0101 MAF System Performance B Yes No
P0102 MAF Sensor Circuit Low Frequency B Yes No
P0103 MAF Sensor Circuit High Frequency B Yes No
P0106 MAP Rationality/Performance B Yes No
P0107 MAP Circuit Low Input Voltage B Yes No
P0108 MAP Circuit Hgh Input Voltage B Yes No
P0112 IAT Circuit Low Input Voltage B Yes No
P0113 IAT Circuit Hgh Input Voltage B Yes No
P0117 ECT Circuit Low Input Voltage B Yes No
P0118 ECT Circuit Hgh Input Voltage B Yes No
P0125 ECT Insufficient for Closed Loop Fuel Control B Yes No
P0128 ECT Below Thermostat Regulating Temperature B Yes No
P0131 O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1) B Yes No
P0132 O2 Sensor Circuit High Voltage (Bank 1 Sensor 1) B Yes No
P0133 O2 Sensor Circuit Slow Response (Bank 1 Sensor 1) B Yes No
P0134 O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1) B Yes No
P0135 O2 Sensor Heater Circuit (Bank 1 Sensor 1) B Yes No
P0153 O2 Sensor Circuit Slow Response (Bank 2 Sensor 1) B Yes No
P0171 O2 Sensor – System too Lean (Bank 1) B Yes No
P0172 O2 Sensor – System too Rich (Bank 1) B Yes No
P0174 O2 Sensor – System too Lean (Bank 2) B Yes No

MIL RPL
(Check (Reduced
Enigne Power
Lamp) Lamp)
P0175 O2 Sensor – System too Rich (Bank 2) B Yes No
P0201 Injector 1 Control Circuit A Yes No
P0300 Engine Misfire Detected B Yes No
P0301 Engine Misfire Detected Cylinder #1 B Yes No
P0325 ION Sensing Module Knock Intensity Circuit B Yes No
P0336 CKP Sensor Circuit Range/Performance (58X) B Yes No
P0337 CKP Sensor Circuit No signal (58X) B Yes No
P0341 CMP Sensor Circuit Range/Performance C No No
P0342 CMP Sensor Circuit No signal C No No
P0351 Injection 1 Control Circuit A Yes No
P0352 Ignition 2 Control Circuit A Yes No
P0401 EGR Flow Insufficient B Yes No
P0402 EGR Flow Excessive B Yes No
P0404 EGR Range/Performance (Open Valve) B Yes No
P0405 EGR Sensor Circuit Low Voltge B Yes No
P0406 EGR Sensor Circuit High Voltge B Yes No
P0420 Catalyst System Low Efficiency (Bank 1) A Yes No
P0430 Catalyst System Low Efficiency (Bank 2) A Yes No
P0440 EVAP Control System B Yes No
P0442 EVAP Control System Small Leak Deteced B Yes No
P0446 EVAP Control System Vent Valve Blocked B Yes No
P0452 EVAP Control System Tank Pressure Sensor Low Input B Yes No
P0453 EVAP Control System Tank Pressure Sensor High Input B Yes No
P0456 EVAP Control System Very Small Leak Deteced C No No
P0461 Fuel Level Sensor Circuit Range/Performance B Yes No
P0462 Fuel Level Sensor Circuit Low Input Voltage B Yes No

MIL RPL
(Check (Reduced
Enigne Power
Lamp) Lamp)
P0463 Fuel Level Sensor Circuit High Input Voltage B Yes No
P0502 No VSS Signal B Yes No
P0506 Idle Speed Control RPM too Low B Yes No
P0507 Idle Speed Control RPM too High B Yes No
P0562 System Voltge is Low D No No
P0563 System Voltge is High B Yes No
P0565 Cruise Main Circuit (Refer to Chassis Electrical) D No No
P0566 Cruise Cancel Circuit (Refer to Chassis Electrical) D No No
P0567 Cruise Resume Circuit (Refer to Chassis Electrical) D No No
P0568 Cruise Set Circuit (Refer to Chassis Electrical) D No No
P0575 Cruise Analog Input Circuit (Refer to Chassis Electrical) C No No
P0601 PCM/ECM Memory Checksum A Yes No
P0602 PCM/ECM Programming error D No No
P0604 PCM/ECM RAM error D No No
P0606 PCM/ECM Internal Preformance D No No
P1106 MAP Circuit Intermittent High Voltage) D No No
P1107 MAP Circuit Intermittent Low Input Voltage D No No
P1111 IAT Circuit Intermittent High Voltage D No No
P1112 IAT Circuit Intermittent Low Input Voltage D No No
P1114 ECT Circuit Intermittent Low Voltage D No No
P1115 ECT Circuit Intermittent High Voltage D No No
P1120 TPS1 Circuit D No No
P1125 ETC Limit Performance Mode A Yes Yes
P1133 O2 Sensor – Too Few Rich/Lean and Lean/Rich Switches (Bank B Yes No
1 Sensor 1)
P1134 O2 Sensor – Transition Switch Time ratio (Bank 1 Sensor 1) B Yes No
P1153 O2 Sensor – Too Few Rich/Lean and Lean/Rich Switches (Bank B Yes No
2 Sensor 1)
P1154 O2 Sensor – Transition Switch Time ratio (Bank 2 Sensor 1) B Yes No
P1167 Fuel supply System RICH During Decel Fuel Cut Off D No No
P1169 Fuel supply System RICH During Decel Fuel Cut Off D No No
P1171 Fuel supply System Lean During Power Enrichment D No No
P1220 TPS2 Circuit D No No
P1221 TPS1–TPS2 Correlation (Circuit Performance) D No No
P1271 APS1–APS2 Correlation (Circuit Performance) D No No
P1275 APS1 Circuit D No No
P1290 ETC Forced Idle Mode A Yes Yes

MIL RPL
(Check (Reduced
Enigne Power
Lamp) Lamp)
P1295 ETC Power Management Mode A Yes Yes
P1299 ETC Forced Engine Shotdown Mode A Yes Yes
P1310 ION Sensing Module Diagnostic A Yes No
P1311 ION Sensing Module SEC 1 Line Circuit Fault A Yes No
P1312 ION Sensing Module SEC 2 Line Circuit Fault A Yes No
P1326 ION Sensing Module Combustion Quality circuit A Yes No
P1340 ION Sensing Module – Cylinder Synchronization B Yes No
P1404 EGR Range/Performance (Closed Valve) B Yes No
P1441 EVAP Control System Comtinuous Open Puege Flow B Yes No
P1514 TPS–MAF Correlation A Yes No
P1515 Command–Acrual TPS Correlation A Yes No
P1516 Command–Acrual TPS Correlation Error A Yes No
P1523 Throttle Actuator Control Return Performance D No No
P1625 PCM/ECM System Reset C No No
P1635 Reference Voltage #1 Ciecuit D No No
P1639 Reference Voltage #2 Ciecuit D No No
P1640 ODM Output circuit Fault D No No
P1650 QDM Output Circuit Fault D No No
Diagnostic Trouble Code (DTC) P0101 MAF System Performance
D06RY00164
Circuit Description D The PCM will store condition which were present when
the DTC was set as Freeze Frame and in the Failure
The mass air flow (MAF) sensor measures the amount of Records data.
air which passes through it into the engine during a given
time. The powertrain control module (PCM) uses the Conditions for Clearing the MIL/DTC
mass air flow information to monitor engine operating
conditions for fuel delivery calculations. A large quantity D The PCM will turn the MIL “OFF” on the third
consecutive trip cycle during which the diagnostic has
of air entering the engine indicates an acceleration or high been run and the fault condtion is no longer present.
load situation, while a small quantity or air indicates
D A history DTC P0101 will clear after 40 cosecutive trip
deceleration or idle. cycle during which the warm up cycles have occurred
The MAF sensor produces a frequency signal which can without a fault.
be monitored using a Tech 2. The frequency will vary D DTC P0101 can be cleared using the Tech 2 “Clear
within a range of around 4 to 7g/s at idle to around 25 to Info” function or by disconnecting the PCM battery
40g/s at maximum engine load. DTC P0101 will be set if feed.
the signal from the MAF sensor does not match a
predicted value based on throttle position and engine Diagnostic Aids
RPM. An intermittent may be caused by the following:
D Poor connections.
Conditions for setting the DTC
D Mis routed harness.
D The engine is running. D Rubbed through wire insulation.
D No TP sensor and MAP sensor DTCs are set. D Broken wire inside the insulation.
D No MAF frequency DTCs are set. D he duct work at the MAF sensor for leaks.
D System voltage is between 11.5 volts and 16 volts. D An engine vacuum leak.
D The PCV system for vacuum leaks.
Action Taken When the DTC Sets
D An incorrect PCV valve.
D The PCM will illuminate the malfunction indicator lamp D The engine oil dip stick not fully seated.
(MIL) the first time the fault is detected.
D The engine oil fill cap loose or missing.
D The PCM calculates an air flow value based on idle air
control valve position, throttle position, RPM and Check for the following conditions:
barometric pressure.
D Poor connection at PCM-Inspect harness connectors A change in the display will indicate the location of
for backed out terminals, improper mating, broken the fault.
locks, improperly formed or damaged terminals, and
poor terminal to wire connection. If DTC P0101 cannot be duplicated, the
information included in the Faillure Records data
D Damaged harness- Inspect the wiring harness for
damage. If the harness appears to be OK, observe the can be useful in determined vehicle mileage since
Mass Air Flow (MAF) display on the Tech 2 while the DTC was last set.
moving connectors and wiring harnesses related to the If it is determined that the DTC occurs
sensor. intermittently, performing the DTC P001
D Plugged intake air duct or filter element Diagnostic Chart may isolate the cause of the
D A wide–open throttle acceleration from a stop should fault.
cause the mass air flow displayed on a Tech 2 to
increase from about 3–6 g/s at idle to 100 g/s or greater
at the time of the 1–2 shift. If not, check for a restriction.
DTC P0101 – MAF System Performance

performed? System
2. Disconnect the Mass Air Flow (MAF) Sensor
harness connector from the MAF Sensor.
3. Place an unpowered test lamp between the 12 volt
signal circuit and the ground circuit, both at the MAF
Sensor connector.
4. Ignition “ON,” Engine“OFF.”
Did the test lamp illuminate? — Go to Step 6 Go toStep 3
3 1. Ignition “ON,” Engine “OFF.”
2. Using a Digital Voltmeter (DVM), check the 12 volt
signal circuit for the correct voltage.
Did the DVM indicate a value within the following 11.5 to 12.5
range? Volt Go to Step 5 Go to Step 4
2. Check the 12 volt signal circuit for the following
conditions:
D An open circuit
D A short to ground
Was the problem found? — Verify repair —
5 Check the MAF ground circuit for the following
conditions:
D An open circuit
D A short to voltage
Was a problem found? — Verify repair —
2. Check the MAF Sensor signal circuit between the
PCM and the MAF Sensor for the following
conditions:
D An open circuit
D A short to ground
D A short to battery voltage
DTC P0101 – MAF System Performance (Cont'd)

7 1. Connect the MAF Sensor wiring harness connector
to the MAF Sensor.
2. Connect the Tech 2 to the vehicle.
3. Place the Transmission in Park/Neutral, and fully
apply the Parking Brake.
5. Select the Mass Air Flow (MAF) parameter on the
Tech 2.
With the engine idling, does the Tech 2 display the
following value(s)? 4 to 7 g/s Go to Step 8 Go toStep 9
8 Observe the Tech 2 value while increasing the engine
RPM to its upper limit.
Does the Tech 2 display the following value(s)? 25 to 40 g/s Go to Step 10 Go toStep 9
9 Replace the MAF Sensor.
10 Replace the PCM.
IMPORTANT: The PCM must be reprogrammed. Refer
to PCM reprogramming.
Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency
D06RY00164
Circuit Description D The PCM will store conditions which were present
when the DTC was set as Freeze Frame and in the
The mass air flow (MAF) sensor measures the amount of Failure Records data.
air which passes through it into the engine during a given
time. The powertrain control module (PCM) uses the Conditions for Clearing the MIL/DTC
mass air flow information to monitor engine operating
conditions for fuel delivery calculations. A large quantity D The PCM will turn the MIL “OFF” on the third
of air entering the engine indicates an acceleration or high been run and the fault condition is no longer present.
load situation, while a small quantity of air indicates
D A history DTC P0102 will clear after 40 consecutive
deceleration or idle. warm-up cycles have occurred without a fault.
The MAF sensor produces a frequency signal which can
D DTC P0102 can be cleared by using the Tech 2 “Clear
be monitored using a Tech 2. The frequency will vary Info” function or by disconnecting the PCM battery
within a range of around 4 to 7g/s at idle to around 25 to 40 feed.
g/s at maximum engine load. DTC P0102 will be set if the
signal from the MAF sensor is below the possible range of Diagnostic Aids
a normally operating MAF sensor. Check for the following conditions:
D Poor connection at PCM – Inspect harness connectors
Conditions for Setting the DTC for backed-out terminals, improper mating, broken
D The engine is running above 500 RPM for greater than locks, improperly formed or damaged terminals, and
10 seconds. poor terminal-to-wire connection.
D System voltage is above 11.5 volts. D Misrouted harness – Inspect the MAF sensor harness
D MAF signal frequency is below 1.6g/s for a total of to ensure that it is not routed too close to high voltage
50-percent of the last 1000 samples monitored. A wires.
sample is taken every cylinder event. D Damaged harness – Inspect the wiring harness for
damage. If the harness appears to be OK, observe the
Action Taken When the DTC Sets Tech 2 while moving connectors and wiring harnesses
related to the MAF sensor. A change in the display will
D The PCM will illuminate the malfunction indicator lamp indicate the location of the fault.
(MIL) the first time the fault is detected. D Plugged intake air duct or filter element – A wide-open
D The PCM calculates an air flow value based on idle air throttle acceleration from a stop should cause the
control valve position, throttle position, RPM and mass air flow displayed on a Tech 2 to increase from
about 3-6 g/second at idle to 100 g/second or greater 2. This step verifies that the problem is present at idle.
at the time of the 1-2 shift. If not, check for a restriction. 4. A voltage reading of less than 4 or over 5 volts at the
If DTC P0102 cannot be duplicated, the information MAF sensor signal circuit indicates a fault in the
included in the Failure Records data can be useful in wiring or a poor connection.
determining vehicle mileage since the DTC was last set.
5. This verifies that ignition feed voltage and a good
Test Description ground are available at the MAF sensor.
Diagnostic Chart.
DTC P0102 – MAF Sensor Circuit Low Frequency

performed? System
2. With the engine idling, monitor “MAF Frequency”
display on the Tech 2.
Is the “MAF Frequency” below the specified value? 1.6 g/s Go to Step 4 Go to Step 5
3 1. Ignition “ON,” engine “OFF.”
2. Review and record Tech 2 Failure Records data.
3. Operate the vehicle within Failure Records
conditions as noted.
4. Using a Tech 2, monitor “DTC” info for DTC P0102. Refer to
Does the Tech 2 indicate DTC P0102 failed this Diagnostic
ignition? — Go to Step 4 Aids
2. Disconnect the MAF sensor connector.
4. Using a DVM, measure voltage between the MAF
sensor signal circuit and battery ground.
Is the voltage near the specified value? 5V Go to Step 5 Go to Step 8
5 Connect a test light between the MAF sensor ignition
feed and ground circuits at the MAF sensor harness
connector.
6 Connect a test light between the MAF sensor ignition
feed circuit and battery ground.
7 1. Check for a poor connection at the MAF sensor.
2. If a poor connection is found, replace the faulty
terminal(s).
Was a poor connection found? — Verify repair Go to Step 11
2. Disconnect the MAF sensor.
3. Disconnect the PCM connector for the MAF signal
circuit.
5. With the DVM, measure the voltage between the
MAF signal terminal at the PCM and battery ground.
Is the voltage under the specified value? 4V Go to Step 9 Go to Step 10
DTC P0102 – MAF Sensor Circuit Low Frequency (Cont'd)

2. Disconnect the PCM connector.
4. Check the MAF sensor signal circuit for a short to 5
volts.
4. Check the MAF sensor signal circuit between the
PCM and the MAF sensor for an open, short to
ground, or short to the MAF ground circuit.
11 Locate and repair the open in the ground circuit to the
MAF sensor.
12 Locate and repair the open in the ignition feed circuit to
the MAF sensor.
13 Replace the MAF sensor.
14 Replace the PCM.
procedures.
Diagnostic Trouble Code (DTC) P0103 MAF Sensor Circuit High Frequency
D06RY00164
Circuit Description Action Taken When the DTC Sets

The mass air flow (MAF) sensor measures the amount of D The PCM will illuminate the malfunction indicator lamp
air which passes through it into the engine during a given (MIL) the first time the fault is detected.
time. The powertrain control module (PCM) uses the D The PCM calculates an airflow value based on idle air
mass air flow information to monitor engine operating control valve position, throttle position, RPM and
conditions for fuel delivery calculations. A large quantity barometric pressure.
of air entering the engine indicates an acceleration or high D The PCM will store conditions which were present
load situation, while a small quantity of air indicates when the DTC was set as Freeze Frame and in the
deceleration or idle. Failure Records data.
The MAF sensor produces a frequency signal which can
be monitored using a Tech 2. The frequency will vary Conditions for clearing the MIL/DTC
within a range of around 4 to 7g/s at idle to around 25 to 40 D The PCM will turn the MIL “OFF” on the third
g/s at maximum engine load. DTC P0103 will be set if the consecutive trip cycle during which the diagnostic has
signal from the MAF sensor is above the possible range of been run and the fault condition is no longer present.
a normally operating MAF sensor. D A history DTC P0103 will clear after 40 consecutive
warm-up cycles have occurred without a fault.
Conditions for Setting the DTC D DTC P0103 can be cleared by using the Tech 2 “Clear
Info” function or by disconnecting the PCM battery
D The engine is running above 500 RPM for more than feed.
10 seconds.
D System voltage is above 11.5 volts. Diagnostic Aids
D MAF signal frequency is above 40g/s for a total of 50 If DTC P0103 cannot be duplicated, the information
percent of the last 200 samples monitored. A sample included in the Failure Records data can be useful in
is taken every cylinder event.
Test Description
Diagnostic Chart.
2. This step verifies that the problem is present at idle.
4. A frequency reading with the MAF sensor connector
disconnected indicates an electromagnetic
interfernce (EMI) related fault.
an electrically erasable programmable read only
memory (EEPROM). When the PCM is being
replaced, the new PCM must be programmed.
Refer to PCM Replacement and Programming
Procedures in Powertrain Control Module (PCM)
and Sensor.
DTC P0103 – MAF Sensor Circuit High Frequency

performed? System
Is “MAF Frequency” above the specified value? 40g/s Go to Step 4 Go to Step 7
3. Ignition “ON,” engine idling.
4. Using a Tech 2, monitor “MAF Frequency.”
Does the Tech 2 indicate a “MAF Frequency” at the
specified value? 0g/s Go to Step 5 Go to Step 6
6 1. Check the MAF harness for incorrect routing near
high voltage components (solenoids, relays,
motors).
2. If incorrect routing is found, correct the harness
routing.
7 1. With the engine idling, monitor “MAF Frequency”
2. Quickly snap open throttle to wide open throttle
while under a road load and record value.
Does the Tech 2 indicate “MAF Frequency” above the
8 Replace the PCM.
procedures.
Diagnostic Trouble Code (DTC) P0106 MAP System Performance
D06RY00165
Circuit Description D The MAP value must vary for a total of 10 seconds over
a 20-second period of time that the samples were
The manifold absolute pressure (MAP) sensor responds monitored.
to changes in intake manifold pressure (vacuum). The
D The failure must occur for 2 consecutive trips.
MAP sensor signal voltage to the powertrain control
module (PCM) varies from below 2 volts at idle (high Action Taken When the DTC Sets
vacuum) to above 4 volts at wide-open throttle (low
vacuum) at sea level. D The PCM will illuminate the malfunction indicator lamp
The MAP sensor is used to determine: manifold pressure (MIL) after the second consecutive trip in which the
fault is detected.
changes while the linear exhaust gas recirculation (EGR)
flow test diagnostic is being run (refer to DTC P0401), D The PCM will default to a BARO value of 79.3 kPa.
engine vacuum level for some other diagnostics, and D The PCM will store conditions which were present
barometric pressure (BARO). The PCM compares the Failure Records data.
MAP sensor signal to a calculated MAP based on throttle
position and various engine load factor. If the PCM Conditions for Clearing the MIL/DTC
detects a MAP signal that varies excessively above or
below the calculated value, DTC P0106 will set. D The PCM will turn the MIL “OFF” on the third
been run and the fault condition is no longer present.
Conditions for Setting the DTC
D No TP sensor DTCs are present. warm-up cycles have occurred without a fault.
D Engine speed is steady, changing less then 100 RPM. D DTC P0106 can be cleared by using the Tech 2 “Clear
D Throttle position is steady, throttle angle changes less Info” function or by disconnecting the PCM battery
than 1%. feed.
D EGR flow rate is steady, changing less than 4%.
D No change in brake switch, A/C clutch, TCC or power
Diagnostic Aids
steering pressure switch status. Check for the following conditions:
D Above conditions are met for longer than 1 second. D Poor connection at PCM – Inspect harness connectors
D Actual MAP value varies more than 10 kPa. for backed-out terminals, improper mating, broken
poor terminal-to-wire connection.
D Damaged harness – Inspect the wiring harness for determining vehicle mileage since the DTC was last set.
damage. If the harness appears to be OK, observe the If it is determined that the DTC occurs intermittently,
MAP display on the Tech 2 while moving connectors performing the DTC P1107 Diagnostic Chart may isolate
and wiring harnesses related to the sensor. A change the cause of the fault.
in the display will indicate the location of the fault.
If DTC P0106 cannot be duplicated, the information
included in the Failure Records data can be useful in
DTC P0106 – MAP System Performance

performed? System
4. Using a Tech 2, monitor “DTC” info for DTC P0106.
Does the Tech 2 indicate DTC P0106 failed? — Go to Step 4 Go to Step 3
3 1. Check for the following conditions:
D Vacuum hoses disconnected, damaged, or
incorrectly routed;
D Intake manifold vacuum leaks;
D Vacuum leaks at throttle body;
D Vacuum leaks at EGR valve flange and pipes;
D Crankcase ventilation valve faulty, missing or
incorrectly installed.
Refer to
2. If a problem is found, repair as necessary. Diagnostic
Was a problem found? — Verify repair Aids
4 1. Disconnect the MAP sensor electrical connector.
2. Observe the MAP value displayed on the Tech 2.
Is the MAP value near the specified value? 11 kPa Go to Step 5 Go to Step 13
5 1. Connect a test light between B+ and the MAP
sensor signal circuit at the MAP sensor harness
connector.
6 1. Jumper the 5 volt reference circuit and the MAP
signal circuit together at the MAP sensor harness
connector.
2. Disconnect the PCM and check the sensor ground
circuit for high resistance, an open between the
PCM and the MAP sensor, or for a poor connection
at the PCM.
DTC P0106 – MAP System Performance (Cont'd)

8 1. Check the 5 volt reference circuit for high
resistance, an open between the PCM and the MAP
sensor, or a poor connection at the PCM.
2. Disconnect the PCM, and check the MAP sensor
signal circuit for high resistance, an open, a short to
ground, or a short to the sensor ground circuit.
10 1. Check the MAP sensor signal circuit for a poor
Did the terminal require replacement? — Verify repair Go to Step 14
11 1. Check for a poor connection at the MAP sensor.
12 Replace the MAP sensor.
13 1. Ignition “OFF,” disconnected the PCM.
2. Ignition “ON,” check the MAP signal circuit for a
short to voltage or a short to the 5 volt reference
circuit.
14 Replace the PCM.
procedures.
Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage
D06RY00165

The manifold absolute pressure (MAP) sensor responds D The PCM will illuminate the malfunction indicator lamp
to changes in intake manifold pressure (vacuum). The (MIL) the first time the fault is detected.
MAP sensor signal voltage to the powertrain control D The PCM will default to a BARO value of 79.3 kPa.
module (PCM) varies from below 2 volts at idle (high D The PCM will store conditions which were present
vacuum) to above 4 volts with the ignition “ON,” engine when the DTC was set as Freeze Frame and in the
not running or at wide-open throttle (low vacuum). Failure Records data.
The MAP sensor is used to determine manifold pressure
changes while the exhaust gas recirculation (EGR) flow Conditions for Clearing the MIL/DTC
test diagnostic is being run (refer to DTC P0401), to D The PCM will turn the MIL “OFF” on the third
determine engine vacuum level for some other consecutive trip cycle during which the diagnostic has
diagnostics and to determine barometric pressure been run and the fault condition is no longer present.
(BARO). The PCM monitors the MAP signals for voltages D A history DTC P0107 will clear after 40 consecutive
outside the normal range of the MAP sensor. If the PCM warm-up cycles have occurred without a fault.
detects a MAP signal voltage that is excessively low, DTC D DTC P0107 can be cleared by using the Tech 2 “Clear
P0107 will be set. Info” function or by disconnecting the PCM battery
feed.
Diagnostic Aids
D No TP sensor DTCs present.
D Engine is running.
D Check for intermittent codes.
D Throttle angle is above 1% if engine speed is less than
1000 RPM. D The MAP sensor shares a 5 Volt reference with the
Fuel Tank Pressure Sensor. If these codes are also
D Throttle angle is above 2% if engine speed is above set, it could indicate a problem with the 5 Volt reference
1000 RPM. circuit .
D The MAP sensor indicates manifold absolute pressure D The MAP sensor shares a ground with the Fuel Tank
at or below 11 kPa for a total of approximately 10 Pressure Sensor, the ECT sensor, and the
seconds over a 16-second period. Transmission Fluid Temperature sensor.
D Ignition voltage more than 11 volts. D Poor connection at PCM – Inspect harness connectors
for backed-out terminals, improper mating, broken
locks, improperly formed or damaged terminals, and If DTC P0107 cannot be duplicated, the information
poor terminal-to-wire connection. included in the Failure Records data can be useful in
D Damaged harness – Inspect the wiring harness for determining vehicle mileage since the DTC was last set.
damage. If the harness appears to be OK, observe the If it is determined that the DTC occurs intermittently,
DTC P0107 – MAP Sensor Circuit Low Voltage

performed? System
2. With the throttle closed, observe the MAP value
displayed on the Tech 2. 0 V 11 kPa
Is the MAP value near the specified value? at sea level Go to Step 4 Go to Step 3
Refer to
4. Using a Tech 2, monitor “DTC” info for DTC P0107. Diagnostic
Does the Tech 2 indicate DTC P0107 failed? — Go to Step 4 Aids
2. Disconnect the MAP sensor electrical connector.
3. Jumper the 5 volt reference circuit and the MAP
signal together at the MAP sensor harness
connector.
Is the MAP value near the specified value? (If no, start
with diagnosis chart for other sensors in the circuit and
see if 5V returns.) 5 V 104 kPa Go to Step 10 Go to Step 5
5 1. Disconnect the jumper.
2. Connect a test light between B+ and the MAP
sensor signal circuit at the MAP sensor harness
connector.
Is the MAP value near the specified value. 5 V 104 kPa Go to Step 6 Go to Step 8
2. Disconnect the PCM and check the 5 volt reference
circuit for an open or short to ground.
3. If the 5 volt reference circuit is open or shorted to
ground, repair it as necessary.
Was the 5 volt reference circuit open or shorted to
ground? — Verify repair Go to Step 7
7 Check the 5 volt reference circuit for a poor connection
at the PCM and replace the terminal if necessary.
DTC P0107 – MAP Sensor Circuit Low Voltage (Cont'd)

2. Disconnect the PCM, and check the MAP signal
circuit for an open, short to ground, or short to the
sensor ground circuit.
3. If the MAP sensor signal circuit is open or shorted to
ground, repair it as necessary.
Was the MAP signal circuit open or shorted to ground? — Verify repair Go to Step 9
9 Check the MAP sensor signal circuit for a poor
connection at the PCM and the MAP sensor; replace
the terminal if necessary.
11 Replace the PCM.
procedures.
Diagnostic Trouble Code (DTC) P0108 MAP Sensor Circuit High Voltage
D06RY00165
Circuit Description D The PCM will default to a BARO value of 79.3 kPa.
The manifold absolute pressure (MAP) sensor responds D The PCM will store conditions which were present
to changes in intake manifold pressure (vacuum). The when the DTC was set as Freeze Frame and in the
Failure Records data.
MAP sensor signal voltage to the powertrain control
module (PCM) varies from below 2 volts at idle (high Conditions for Clearing the MIL/DTC
vacuum) to above 4 volts with the key “ON,” engine not
running or at wide-open throttle (low vacuum). D The PCM will turn the MIL “OFF” on the third
The MAP sensor is used to determine manifold pressure consecutive trip cycle during which the diagnostic has
changes while the linear EGR flow test diagnostic is being
run (refer to DTC P0401), to determine engine vacuum D A history DTC P0108 will clear after 40 consecutive
level for some other diagnostics and to determine
barometric pressure (BARO). The PCM monitors the Info” function or by disconnecting the PCM battery
MAP signals for voltages outside the normal range of the feed.
MAP sensor. If the PCM detects a MAP signal voltage
that is excessively high, DTC P0108 will be set. Diagnostic Aids
D The MAP sensor shares a 5 Volt reference with the
D No TP sensor DTCs present. Fuel Tank Pressure Sensor. If these codes are also set,
D Engine is running for more than 10 seconds. it could indicate a problem with the 5 Volt reference
D Throttle position is below 3% if engine speed is below circuit.
1000 RPM. D The MAP sensor shares a ground with the Fuel Tank
D Throttle position is below 10% if engine speed is above Pressure Sensor (Vapor Pressure Sensor), the ECT
1000 RPM. sensor, and the Transmission Fluid Temperature
sensor.
D The MAP sensor indicates an intermittent manifold
absolute pressure above 80 kPa for a total of D Poor connection at PCM – Inspect harness connectors
approximately 10 seconds over a 16-second period. for backed-out terminals, improper mating, broken
D The PCM will illuminate the malfunction indicator lamp
D Damaged harness – Inspect the wiring harness for determining vehicle mileage since the DTC was last set. If
damage. If the harness appears to be OK, observe the it is determined that the DTC occurs intermittently,
DTC P0108 – MAP Sensor Circuit High Voltage

performed? System
2 1. If the engine idle is rough, unstable or incorrect,
repair the idle problem before using this chart. Refer
to Symptoms section.
2. With the engine idling, note the MAP value on the
Tech 2.
Is the MAP reading above the specified value? 90 kPa Go to Step 4 Go to Step 3
2. Disconnect the MAP sensor electrical connector.
4. Note the MAP sensor voltage displayed on the Tech
2. (If no, start with diagnostic chart for other sensors
in the circuit and see if 5V returns.) 11 kPa 0.0
Is the MAP sensor voltage at the specified value? V Go to Step 5 Go to Step 6
5 Probe the sensor ground circuit with a test light to B+.
6 1. Check the MAP signal circuit for a short to voltage or
a short to the 5 volt reference circuit.
2. If the MAP sensor signal circuit is shorted, repair
circuit as necessary.
Was the MAP sensor signal circuit shorted? — Verify repair Go to Step 11
7 1. Check for a poor sensor ground terminal connection
at the MAP sensor electrical connector.
2. If a problem if found, replace the faulty terminal.
8 Check for a plugged or leaking vacuum supply to the
MAP sensor.
Is the vacuum supply plugged or leaking? — Verify repair Go to Step 12
9 1. Check for a poor sensor ground terminal connection
at the PCM.
2. If a problem is found, replace the faulty terminal.
DTC P0108 – MAP Sensor Circuit High Voltage (Cont'd)

10 1. Check the continuity of the MAP sensor ground
circuit.
2. If the MAP sensor ground circuit measures over 5
ohms, repair open or poor connection.
Was a condition found and corrected? — Verify repair Go to Step 11
11 Replace the PCM.
procedures.
Is the action complete? — Verify Repair —
Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage
D06RY00168
Circuit Description Conditions for Clearing the MIL/DTC

The intake air temperature (IAT) sensor is a thermistor D The PCM will turn the MIL “OFF” on the third
which measures the temperature of the air entering the consecutive trip cycle during which the diagnostic has
engine. The powertrain control module (PCM) applies 5 been run and the fault condition is no longer present.
volts through a pull-up resistor to the IAT sensor. When D A history DTC P0112 will clear after 40 consecutive
the intake air is cold, the sensor resistance is high and the warm-up cycles have occurred without a fault.
PCM will monitor a high signal voltage on the IAT signal D DTC P0112 can be cleared by using the Tech 2 “Clear
circuit. If the intake air is warm, the sensor resistance is Info” function or by disconnecting the PCM battery
lower, causing the PCM to monitor a lower voltage. DTC feed.
P0112 will set when the PCM detects an excessively low
signal voltage on the intake air temperature sensor signal Diagnostic Aids
circuit. Check for the following conditions:
Conditions for Setting the DTC for backed-bout terminals, improper mating, broken
D The engine has been running for over 2 minutes. poor terminal-to-wire connection.
D Vehicle speed is greater than 30 mph (48 km/h) . D Damaged harness – Inspect the wiring harness for
D IAT signal voltage indicates and intake air temperature damage. If the harness appears to be OK, observe the
greater than 148°C (298°F) (about 5 volts) for a total IAT display on the Tech 2 while moving connectors and
of 12.5 seconds over a 25-second period of time. wiring harnesses related to the IAT sensor. A change
in the IAT display will indicate the location of the fault.
Action Taken When the DTC Sets If DTC P0112 cannot be duplicated, the information
D The PCM will illuminate the malfunction indicator lamp included in the Failure Records data can be useful in
(MIL) the first time the fault is detected. determining vehicle mileage since the DTC was last set.
D The PCM will store conditions which were present
Test Description
Diagnostic Chart:
2. Verifies that the fault is present.
3. If DTC P0112 can be repeated only by duplicating
the Failure Records condition, refer to the
Temperature vs. Resistance Value table. The table
may be used to test the IAT sensor at various
temperatures to evaluate the possibility of a
“shifted” sensor that may be stored above or below
a certain temperature. If this is the case, replace
the IAT sensor. If the IAT sensor appears to be OK,
the fault is intermittent; refer to Diagnostic Aids.

°C °F OHMS
Temperature vs. Resistance Values
(approximate)
100 212 177
80 176 332
60 140 667
45 113 1188
35 95 1802
25 77 2796
15 59 4450
5 41 7280
–5 23 12300
–15 5 21450
–30 –22 52700
–40 –40 100700
DTC P0112–IAT Sensor Circuit Low Voltage

performed? System
2. Using a Tech 2, monitor the intake air temperature
(IAT).
Is the intake air temperature greater than the specified 148°C
value? (283°F) Go to Step 4 Go to Step 3
3 1. Ignition “ON,” engine “OFF.” Review and record
Tech 2 Failure Records data.
3. Using a Tech 2, monitor the “DTC” info for DTC
P0112. Refer to
Does the Tech 2 indicate DTC P0112 failed this Refer to Test Diagnostic
ignition? — Description Aids
2. Disconnect the IAT sensor electrical connector.
4. Observe the intake air temperature on the Tech 2. –38°C
Is the intake air temperature below the specified value? (–36°F) Go to Step 6 Go to Step 5
2. Disconnect the PCM electrical connectors.
3. Check the IAT sensor signal circuit for a short to
ground.
Is the IAT sensor signal circuit shorted to ground? — Verify repair Go to Step 7
6 Replace the IAT sensor.
7 Replace the PCM.
procedures.
Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage
D06RY00168

The intake air temperature (IAT) sensor is a thermistor D The PCM will turn the MIL “OFF” on the third
which measures the temperature of the air entering the consecutive trip cycle during which the diagnostic has
engine. The powertrain control module (PCM) applies 5 been run and the fault condition is no longer present.
circuit. If the intake air is warm, the sensor resistance is Info” function or by disconnecting the PCM battery
lower causing the PCM to monitor a lower voltage. DTC feed.
P0113 will set when the PCM detects an excessively high
signal voltage on the intake air temperature sensor signal Diagnostic Aids
circuit. Check for the following conditions:
D The IAT sensor shares a ground with the EGR position
Conditions for Setting the DTC sensor and the TP sensor. Check the ground if these
DTC’s are set.
D The engine has been running for over 4 minutes.
D Vehicle speed is less than 20 mph (32 km/h). for backed-out terminals, improper mating, broken
D ECT signal temperature is above 60°C (140°F). locks, improperly formed or damaged terminals, and
D Mass air flow is less then 20 g/second. poor terminal-to-wire connection.
D IAT signal voltage indicates an intake air temperature D Damaged harness – Inspect the wiring harness for
less than –39°C (–38°F) for total of 12.5 seconds over damage. If the harness appears to be OK, observe the
a 25-second period. IAT display on the Tech 2 while moving connectors and
wiring harnesses related to the IAT sensor. A change
Action Taken When the DTC Sets in the IAT display will indicate the location of the fault.
D The PCM will illuminate the malfunction indicator lamp included in the Failure Records data can be useful in
Test Description Intake Air Temperature Sensor
Diagnostic Chart: °C °F OHMS
2. Verifies that the fault is present. Temperature vs. Resistance Values
(approximate)
the Failure Records conditions, refer to the 100 212 177
“Temperature vs. Resistance Values” table. The
80 176 332
table may be used to test the IAT sensor at various
temperatures to evaluate the possibility of a 60 140 667
“shifted” sensor that may be open above or below a
45 113 1188
certain temperature. If this is the case, replace the
IAT sensor. If the IAT sensor appears to be OK, the 35 95 1802
fault is intermittent; refer to Diagnostic Aids.
25 77 2796
15 59 4450
5 41 7280
–5 23 12300
–15 5 21450
–30 –22 52700
–40 –40 100700
DTC P0113 –IAT Sensor Circuit High Voltage

performed? System
2 Ignition “ON,” engine “OFF.” Observe the “Intake Air
Temp” display on the Tech 2.
–38°C
Is the “Intake Air Temp” below the specified value? (–36°F) Go to Step 4 Go to Step 3
2. Review and record Tech 2 Failure Records data
parameters.
Refer to
4. Using a Tech 2, monitor “DTC” info for DTC P0113. Refer to Test Diagnostic
Does the Tech 2 indicate DTC P0113 failed? — Description Aids
2. Disconnect the IAT sensor electrical connector.
3. Jumper the IAT signal circuit and the sensor ground
circuit together at the IAT sensor harness
connector.
5. Observe the “Intake Air Temp” display on the Tech
2. 140°C
Is the “Intake Air Temp” at the specified value? (284°F) Go to Step 6 Go to Step 5
5 1. Jumper the IAT signal circuit at the IAT sensor
harness connector to chassis ground.
2. Observe the “Intake Air Temp” display on the Tech
2. 140°C
Is the “Intake Air Temp” at the specified value? (284°F) Go to Step 7 Go to Step 8
DTC P0113 –IAT Sensor Circuit High Voltage (Cont'd)

6 Check for poor connections at the IAT sensor and
replace terminals if necessary.
Did any terminals require replacement? — Verify repair Go to Step 10
2. Disconnect the PCM, and check the IAT sensor
ground circuit for an open.
3. If the IAT sensor ground circuit is open, repair it as
necessary.
Was the IAT sensor ground circuit open? — Verify repair Go to Step 9
2. Disconnect the PCM, and check the IAT signal
circuit for an open.
3. If the IAT sensor signal circuit is open, repair it as
necessary.
Was the IAT signal circuit open? — Verify repair Go to Step 9
9 Check for a poor sensor ground or IAT signal circuit
terminal connection at the PCM and replace
terminal(s) if necessary.
Did any of the terminals need to be replaced? — Verify repair Go to Step 11
10 Replace the IAT sensor.
11 Replace the PCM.
procedures.
Diagnostic Trouble Code (DTC) P0117 ECT Sensor Circuit Low Voltage
D06RY00169

The engine coolant temperature (ECT) sensor is a D The PCM will turn the MIL “OFF” on the third
thermistor mounted on a coolant crossover pipe at the consecutive trip cycle during which the diagnostic has
front of the engine. The powertrain control module (PCM) been run and the fault condition is no longer present.
applies a voltage (about 5 volts) through a pull-up resistor D A history DTC P0117 will clear after 40 consecutive
to the ECT signal circuit. When the engine coolant is cold, warm-up cycles have occurred without a fault.
the sensor (thermistor) resistance is high, therefore the D DTC P0117 can be cleared by using the Tech 2 “Clear
PCM will measure a high signal voltage. As the engine Info” function or by disconnecting the PCM battery
coolant warms, the sensor resistance becomes lower, feed.
and the ECT signal voltage measured at the PCM drops.
With a fully warmed-up engine, the ECT signal voltage Diagnostic Aids
should measure about 1.5 to 2.0 volts. Check for the following conditions:
D Engine running time is longer than one minute. poor terminal-to-wire connection.
D The ECT sensor signal indicates an engine coolant D Damaged harness – Inspect the wiring harness for
temperature greater than 150°C (302°F) (about 0.10 damage. If the harness appears to be OK, observe the
V) for a total of 50 seconds over a 100–second period. ECT display on the Tech 2 while moving connectors
and wiring harnesses related to the ECT sensor. A
Action Taken When the DTC Sets change in the ECT display will indicate the location of
D The PCM will illuminate the malfunction indicator lamp the fault.
(MIL) the first time the fault is detected. If DTC P0117 cannot be duplicated, the information
D The PCM will substitute the ECT reading with a default included in the Failure Records data can be useful in
engine coolant temperature value. The default value determining vehicle mileage since the DTC was last set.
is based on start-up intake air temperature and running If it is determined that the DTC occurs intermittently,
time. performing the DTC P1114 Diagnostic Chart may isolate
D The PCM will store conditions which were present the cause of the fault.
Test Description
Diagnostic Chart.
the Failure Records conditions, refer to the
“Temperature vs. Resistance Values” table. The
table may be used to test the ECT sensor at various
“shifted” sensor that may be shorted above or below
the ECT sensor. If the ECT sensor appears to be
OK, the fault is intermittent; refer to Diagnostic Aids.
Engine Coolant Temperature Sensor

°C °F OHMS
(approximate)
100 212 177
80 176 332
60 140 667
45 113 1188
35 95 1802
25 77 2796
15 59 4450
5 41 7280
–5 23 12300
–15 5 21450
–30 –22 52700
–40 –40 100700
DTC P0117 – ECT Sensor Low Voltage

performed? System
2. Observe the “Eng Cool Temp” display on the Tech 2. 139°C
Is the “Eng Cool Temp” below the specified value? (282°F) Go to Step 4 Go to Step 3
4 1. Disconnect the ECT sensor electrical connector.
2. Observe the “Eng Cool Temp” display on the Tech 2. –39°C
Is the “Eng Cool Temp” at the specified value? (–38°F) Go to Step 6 Go to Step 5
2. Disconnect the PCM and check the ECT signal
circuit for a short to ground or a short to the sensor
ground circuit.
3. If the ECT signal circuit is shorted. repair it as
necessary.
Was the ECT signal circuit shorted to ground? — Verify repair Go to Step 7
6 Replace the ECT sensor.
7 Replace the PCM.
procedures.
Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage
D06RY00169

The engine coolant temperature (ECT) sensor is a D The PCM will turn the MIL “OFF” on the third
thermistor mounted in on a coolant crossover pipe at the consecutive trip cycle during which the diagnostic has
front of the engine. The powertrain control module (PCM) been run and the fault condition is no longer present.
applies a voltage (about 5 volts) through a pull-up resistor D A history DTC P0118 will clear after 40 consecutive
to the ECT signal circuit. When the engine coolant is cold, warm-up cycles have occurred without a fault.
the sensor (thermistor) resistance is high, therefore the D DTC P0118 can be cleared by using the Tech 2 “Clear
PCM will measure a high signal voltage. As the engine Info” function or by disconnecting the PCM battery
coolant warms, the sensor resistance becomes less, and feed.
the ECT signal voltage measured at the PCM drops. With
a fully warmed-up engine, the ECT signal voltage should Diagnostic Aids
measure about 1.5 to 2.0 volts. Check for the following conditions:
The ECT shares a ground with the Transmission Fluid
Conditions for Setting the DTC Temperature sensor, the Fuel Tank Pressure sensor, and
D Engine running time is longer than 1.5 minutes. the MAP sensor.
Check the ground if these DTCs are also set.
D The ECT sensor signal indicates an engine coolant
temperature of –39°C (–38°F) or less (about 5 volts) D Poor connection at PCM – Inspect harness connectors
for a total of 50 seconds over a 100-second period. for backed-out terminals, improper mating, broken
Action Taken When the DTC Sets poor terminal-to-wire connection.
D Damaged harness – Inspect the wiring harness for
D The PCM will illuminate the malfunction indicator lamp damage. If the harness appears to be OK, observe the
(MIL) the first time the fault is detected. ECT display on the Tech 2 while moving connectors
D The PCM will substitute the ECT reading with a default and wiring harnesses related to the ECT sensor. A
engine coolant temperature value. The default value change in the ECT display will indicate the location of
is based on start-up intake air temperature and running the fault.
time. If DTC P0118 cannot be duplicated, the information
D The PCM will store conditions which were present included in the Failure Records data can be useful in
when the DTC was set as Freeze Frame and in the determining vehicle mileage since the DTC was last set.
Failure Records data. If it is determined that the DTC occurs intermittently,
performing the DTC P1115 Diagnostic Chart may isolate Engine Coolant Temperature Sensor
the cause of the fault.
°C °F OHMS
Test Description
Number(s) below refer to the step number(s) on the (approximate)
Diagnostic Chart.
100 212 177
3. If DTC P0118 can be repeated only by duplicating 80 176 332
the Failure Records conditions, refer to the 60 140 667
“Temperature vs. Resistance Value” table. The
table may be used to test the ECT sensor at various 45 113 1188
temperatures to evaluate the possibility of a 35 95 1802
a certain temperature. If this is the case, replace 25 77 2796
the ECT sensor. If the ECT sensor appears to be 15 59 4450
OK, the fault is intermittent; refer to Diagnostic Aids.
5 41 7280
–5 23 12300
–15 5 21450
–30 –22 52700
–40 –40 100700
DTC P0118 – ECT Sensor Circuit High Voltage

performed? System
2. Observe the “Eng Cool Temp” display on the Tech 2. –39°C
Is the “Eng Cool Temp” below the specified value? (–38°F) Go to Step 4 Go to Step 3
4. Using a Tech 2, monitor the “DTC” info for DTC Refer to
P0118. Refer to Test Diagnostic
Does the Tech 2 indicate DTC P0118 failed? — Description Aids
4 1. Disconnect the ECT sensor electrical connector.
2. Jumper the ECT signal circuit and the sensor
ground circuit together at the ECT sensor harness
connector.
Is the “Eng Cool Temp” at the specified value? (284°F) Go to Step 6 Go to Step 5
5 1. Jumper the ECT signal circuit at the ECT sensor
harness connector to chassis ground.
Is the “Eng Cool Temp” at the specified value? (284°F) Go to Step 7 Go to Step 8
6 Check for poor connections at the ECT sensor and
replace terminals if necessary.
DTC P0118 – ECT Sensor Circuit High Voltage (Cont'd)

2. Disconnect the PCM, and check the ECT sensor
ground circuit for an open.
3. If the ECT sensor ground circuit is open, repair it as
necessary.
Was the ECT sensor ground circuit open? — Verify repair Go to Step 9
2. Disconnect the PCM, and check the ECT signal
circuit for an open.
3. If the ECT sensor signal circuit is open, repair it as
necessary.
Was the ECT signal circuit open? — Verify repair Go to Step 9
9 Check for a poor sensor ground or ECT signal circuit
terminal connection at the PCM and replace
Did any of the terminals need to be replaced? — Verify repair Go to Step 11
11 Replace the PCM.
procedures.
Diagnostic Trouble Code (DTC)

P0125 ECT Excessive Time to Closed Loop Fuel Control
D06RY00169
Circuit Description D For a warm engine (intake air temperature is greater

than 10°C/50°F), engine coolant temperature
To provide the best possible combination of driveability, sufficient to allow “closed loop” operation
fuel economy, and emission control, a “closed loop” (50°C/122°F) is not achieved within 2 minutes of
air/fuel metering system is used. When the vehicle is first start-up. For a cold engine (intake air temperature
started, the powertrain control module (PCM) controls between (–7°C and 10°C), engine coolant
fuel delivery in “open loop,” ignoring the heated oxygen temperature sufficient to allow “closed loop” operation
sensor (HO2S) signals and calculating air/fuel ratio based (50°C/122°F) is not achieved within 10 minutes of
on inputs from the engine coolant temperature, throttle start-up.
position, and mass air flow sensors. The PCM will begin D The above condition fails 20 consecutive times.
using the Bank 1 HO2S 1 and Bank 2 HO2S 1 signals for
controlling fuel delivery under “closed loop” conditions Action Taken When the DTC Sets
when the following conditions have been met: D The PCM will illuminate the malfunction indicator lamp
D The HO2S output signals are varying, indicating that (MIL) after the second consecutive trip in which the
the sensors are hot enough to operate properly. fault is detected.
D The engine coolant temperature sensor indicates D The PCM will store conditions which were present
coolant temperature above 50°C (122°F). when the DTC was set as Freeze Frame and in the
D Time since start-up is at least 16 seconds for a warm
engine or 23 seconds for a cold engine. Conditions for Clearing the MIL/DTC
Conditions for Setting the DTC D The PCM will turn the MIL “OFF” on the third
D No active IAT or ECT DTC(s) are present. been run and the fault condition is no longer present.
D Engine is running. D A history DTC P0125 will clear after 40 consecutive
D Vehicle speed is greater than 5 mph (8 km/h) . warm-up cycles have occurred without a fault.
D Intake air temperature is greater than –10°C (14°F) D DTC P0125 can be cleared by using the Tech 2 “Clear
0°C (32°F). Info” function or by disconnecting the PCM battery
D Start–up engine coolant temperature is between feed.
–10°C (–14°F) and 28°C (82°F).
Diagnostic Aids Engine Coolant Temperature
DTC P0125 set indicates a faulty ECT sensor.
Comparing the engine coolant temperature displayed on °C °F OHMS
a Tech 2 with actual coolant temperature measured with a Temperature vs. Resistance Values
thermometer may isolate this condition. If the displayed (approximate)
engine coolant temperature is not close to the actual 100 212 177
coolant temperature, replace the ECT sensor.
Check for the following conditions: 80 176 332
D Poor connection at PCM – Inspect harness connectors 60 140 667
locks, improperly formed or damaged terminals, and 45 113 1188
poor terminal-to-wire connection. 35 95 1802
damage. If the harness appears to be OK, observe the 25 77 2796
display on the Tech 2 while moving connectors and 15 59 4450
wiring harnesses related to the sensor. A change in the
display will indicate the location of the fault. 5 41 7280
–5 23 12300
determining vehicle mileage wince the DTC was last set. –15 5 21450
–30 –22 52700
Test Description
Number(s) below refer to the step number(s) on the –40 –40 100700
Diagnostic Chart.
2. Comparing the engine coolant temperature displayed
on a Tech 2 with actual coolant temperature
measured with a thermometer may isolate this
condition. If the displayed engine coolant
temperature is not close to the actual coolant
temperature, replace the ECT sensor. If the
temperatures are close, the fault is intermittent;
refer to Diagnostic Aids.
DTC P0125 –ECT Excessive Time to Closed Loop Fuel Control

performed? System
2 Are any ECT sensor DTCs set? Go to
applicable
ECT sensor
— DTC chart Go to Step 3
3 1. Allow the engine to cool completely.
2. Check the cooling system coolant level (refer to
Cooling and Radiator).
Is the coolant level OK? — Go to Step 4 Go to Step 9
2. With the engine idling, monitor “ENG COOL TEMP”
display on the Tech 2. Refer to
Does “ENG COOL TEMP” increase to above the Diagnostic
specified value within 2 minutes? 21°C (70°F) Aids Go to Step 5
5 Check for proper operation of the thermostat (refer to
Cooling and Radiator).
Is the thermostat operating correctly? — Go to Step 6 Go to Step 9
DTC P0125 –ECT Excessive Time to Closed Loop Fuel Control (Cont'd)
6 Compare engine coolant temperature displayed on the
Tech 2 to the actual coolant temperature measured
with a thermometer. (Observe normal precautions
when opening the cooling system.)
Is the Tech 2 engine coolant temperature indication
close to the measured temperature? — Go to Step 9 Go to Step 7
3. Using a DVM, measure the resistance of the ECT at
the PCM connector.
4. Compare the DVM reading with the chart in “Test
Description.”
Is the chart value approximately equal to the
thermometer reading? — Go to Step 12 Go to Step 8
8 Check for high resistance in wiring related to the ECT
sensor. Also, check for poor connections at the ECT
sensor and the PCM.
9 Refer to Cooling and Radiator for cooling system
diagnosis and repair condition as necessary.
10 Replace the faulty terminal(s) or repair faulty wiring as
necessary.
12 Replace the PCM.
procedures.
Diagnostic Trouble Code(DTC)

P0128 Thermostat Insufficient temperrature for Stable Opreation
D06RY00169

D The engine coolant temperature (ECT) sensor D The PCM will turn the MIL “OFF” on the third
thermistor mounted on a coolant crossover pipe at the consecutive trip cycle during which the diagnostic has
front of the engine. been run and the fault condtion is no longer present.
This code determines if system has insufficient D A history DTC P0128 will clear after 40 cosecutive trip
coolant temperatures for stable operation. cycle during which the warm up cycles have occurred
without a fault.
Conditions for setting the DTC D DTC P0128 can be cleared using the Tech 2 “Clear
D Engine running. feed.
D No IAT, ECT and MAF DTCs set. Tech 2 “Clear Info” function or by disconnecting
D No VSS DTC set. the PCM battery feed.
Warm case(Ambient temperature is between 50°F and
128°F.): Diagnostic Aids
Time for coolant to reach stabillzed closed loop value is An intermittent may be caused by the following:
less than 239 sec. D Poor connectons.
Cold case(Ambient temperature is between 20°F and D Mis routed harness.
50°F.):
D Rubbed through wire insulation.
Time for coolant to reach stabillzed thermostat D Broken wire inside the insulation.
regulation temperature is more than 263 sec.
Action Taken When the DTC Sets D Poor connection at PCM–Inspect harness connectors
for backed out terminals,improper mating,broken
D The PCM will illuminate the malfunction indicator locks, improperly formed or damaged terminals,and
lamp(MIL) after the second consecutive trip in which poor terminal to wire connection.
the fault is detected.
D The PCM will store condition which were present when
Records data.
D Damaged harness–Inspect the wiring harness for
damage.
If the harness appears to be OK,observe the ECT
display on the Tech2 while moving connectors and
wiring harnesses related to the sensor.
A change in the display will indicate the location of
the fault.
If DTC P0128 cannot be duplicated, the
can be useful in determined vehicle mileage since
the DTC was last set.
If it is determined that the DTC occurs
intermittently, performing the DTC P0128
Diagnostic Chart may isolate the cause of the
fault.

P0128 Thermostat Insufficient temperrature for stable opreation
1 Was the “On-Board(OBD)System Check”performed? Go to OBD
System
2 1. Visually/physically check air duct and water pipe for
splits, kinks,and proper conections and routing.
2. If a problem is found,repair as necessary.
3 1. Remove and check the filter element for dirt or
restrictions.
2. Replace the air filter element if necessary.
4 1. Remove and check the Thermostat for stable
opreation. Refer to 6B section.
2. Replace the thermostat if necessary.
5 1. Ignition “ON”,engine “OFF”.
2. Review and record Tech 2 Failure Records.
3. Opreate the vehicle within Failure Records
Does the Tech 2 indicate DTC P0128 failed this DiagnosticAid
ignition? — Go to Step 6 s
6 1. Ignition “ON”, engine “OFF”.
2. Oberve the “Eng Cool Temp”display on the Tech 2. 139°C
Is the “Eng Cool Temp” below the specified value? (282°F) Verify repair Go to Step 7
2. Disconnect the PCM and check the ECT signal
circuit for a short to ground or a short to the sensor
ground circuit.
3. If the ECT signal circuit is shorted,repair it as Refer to Diag-
necessary. nostic
8 Replace the PCM.
IMPORTANT:

P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1
D06RY00170

The powertrain control module (PCM) supplies a bias D The PCM will illuminate the malfunction indicator lamp
voltage of about 450 mV between the heated oxygen (MIL) the first time the fault is detected.
sensor (HO2S) signal high and signal low circuits. When D The PCM will store conditions which were present
measured with a 10 megaohm digital voltmeter, this may when the DTC was set as Freeze Frame and in the
display as low as 350 mV. The oxygen sensor varies the Failure Records data.
voltage within a range of about 1000 mV when the D “Open loop” fuel control will be in effect.
exhaust is rich, down through about 10 mV when exhaust
is lean. The PCM constantly monitors the HO2S signal Conditions for Clearing the MIL/DTC
during “closed loop” operation and compensates for a rich D The PCM will turn the MIL “OFF” on the third
or lean condition by decreasing or increasing injector consecutive trip cycle during which the diagnostic has
pulse width as necessary. If the Bank 1 HO2S 1 voltage been run and the fault condition is no longer present.
remains excessively low for an extended period of time, D A history DTC P0131 will clear after 40 consecutive
DTC P0131 will be set. warm-up cycles have occurred without a fault.
Conditions for Setting the DTC Info” function or by disconnecting the PCM battery
feed.
D No related DTCs.
D Vehicle is operating in “closed loop.” Diagnostic Aids
D Engine coolant temperature is above 60°C (140°F). Check for the following conditions:
D “Closed loop” commanded air/fuel ratio is between D Heated oxygen sensor wiring – The sensor pigtail may
14.5 and 14.8. be routed incorrectly and contacting the exhaust
D Throttle angle is between 3% and 19%. system.
D Bank 1 HO2S 1 signal voltage remains below 22 mV D Poor PCM to engine block grounds.
during normal “closed loop” operation for a total of 77 D Fuel pressure – The system will go lean if pressure is
seconds over a 90-second period of time. too low. The PCM can compensate for some
decrease. However, If fuel pressure is too low, a DTC
P0131 may be set. Refer to Fuel System Diagnosis.
D Lean injector(s) – Perform “Injector Balance Test.”
D Vacuum leaks – Check for disconnected or damaged D If none of the above conditions are present, replace the
vacuum hoses and for vacuum leaks at the intake affected HO2S.
manifold, throttle body, EGR system, and PCV system.
D Exhaust leaks – An exhaust leak may cause outside air Test Description
to be pulled into the exhaust gas stream past the Number(s) below refer to step numbers on the diagnostic
HO2S, causing the system to appear lean. Check for chart.
exhaust leaks that may cause a false lean condition to
be indicated. 3. DTC P0131 failing during operation may indicate a
D MAF sensor – The system can go lean if the MAF condition described in the “Diagnostic Aids” above.
sensor signal indicates an engine airfiow If the DTC P0131 test passes while the Failure
measurement that is not correct. Disconnect the MAF Records conditions are being duplicated, an
sensor to see if the lean condition is corrected. If so, intermittent condition is indicated.
replace the MAF sensor. Reviewing the Failure Records vehicle mileage since the
D Fuel contamination – Water, even in small amounts, diagnostic test last failed may help determine how often
can be delivered to the fuel injectors. The water can the condition that caused the DTC to be set occurs. This
cause a lean exhaust to be indicated. Excessive may assist in diagnosing the condition.
alcohol in the fuel can also cause this condition. Refer
to Fuel System Diagnosis for the procedure to check
for fuel contamination.
DTC P0131 –HO2S Circuit Low Voltage Bank 1 Sensor 1

performed? System
2 1. Install the Tech 2.
2. Run the engine at operating temperature.
3. Operate the vehicle within the parameters specified
under “Conditions for Setting the DTC” criteria
included in Diagnostic Support.
4. Using a Tech 2, monitor Bank 1 HO2S 1 voltage.
Does the Bank 1 HO2S 1 voltage remain below the
specified value? 22 mV Go to Step 4 Go to Step 3
3 1. Ignition “ON,” engine “OFF,” review and record Tech
2 Failure Records data and note parameters.
3. Using a Tech 2, monitor “DTC” info for DTC P0131
until the DTC P0131 test runs.
Refer to
Note test result.
Diagnostic
Does Tech 2 indicate DTC P0131 failed this ignition? — Go to Step 4 Aids
3. Check the Bank 1 HO2S 1 high and low circuits for a
short to ground or a short to the heater ground
circuit.
Are the Bank 1 HO2S 1 signal circuits shorted to
5 Repair the Bank 1 HO2S 1 signal circuit.
6 1. Turn the ignition “OFF,” HO2S 1 and PCM
disconnected.
2. Check for continuity between the high and low
signal circuits.
Was there continuity between the high and low circuits? — Go to Step 7 Go to Step 8
DTC P0131 –HO2S Circuit Low Voltage Bank 1 Sensor 1 (Cont'd)

7 Repair the short between the high and low circuits.
2. Reconnect the PCM, leave the sensor
disconnected.
3. Ignition “ON.” Refer to
Does the Tech 2 indicate Bank 1 HO2S 1 voltage Diagnostic
between the specified values? 425-475 mV Aids Go to Step 9
9 Replace the PCM.
procedures.

P0132 HO2S Circuit High Voltage Bank 1 Sensor 1
D06RY00170

sensor (HO2S) signal and low circuits. When measured D The PCM will store conditions which were present
with a 10 megaohm digital voltmeter, this may display as when the DTC was set as Freeze Frame and in the
low as 320 mV. The oxygen sensor varies the voltage Failure Records data.
within a range of about 1000 mV when exhaust is rich, D “Open loop” fuel control will be in effect.
down through about 10 mV when exhaust is lean. The
PCM constantly monitors the HO2S signal during “closed Conditions for Clearing the MIL/DTC
loop” operation and compensates for a rich or lean D The PCM will turn the MIL “OFF” on the third
condition by decreasing or increasing injector pulse width consecutive trip cycle during which the diagnostic has
as necessary. If the Bank 1 HO2S 1 voltage remains been run and the fault condition is no longer present.
excessively high for an extended period of time, DTC D A history DTC P0132 will clear after 40 consecutive
P0132 will be set. warm-up cycles have occurred without a fault.
feed.
D No related DTCs.
D Engine coolant temperature is above 60°C (140°F) Diagnostic Aids
D “Closed loop” commanded air/fuel ratio is between Check the following items:
14.5 and 14.8.
D Fuel pressure – The system will go rich if pressure is
D Throttle angle is between 3% and 19%. too high. The PCM can compensate for some
D Bank 1 HO2S 1 signal voltage remains above 952 mV increase. However, if fuel pressure is too high, a DTC
during normal “closed loop” operation for a total of 77 P0132 may be set. Refer to Fuel System Diagnosis.
seconds over a 90-second period. D Perform “Injector Balance Test” – Refer to Fuel System
OR Diagnosis.
D Bank 1 HO2S 1 signal voltage remains above 500 mV D Check the EVAP canister for fuel saturation – If full of
during “deceleration fuel cutoff mode” operation for 3 fuel, check canister control and hoses. Refer to
seconds. Evaporative (EVAP) Emission Control System.
D MAF sensor –The system can go rich if MAF sensor An HO2S which is faulty and not allowing a full voltage
signal indicates an engine airflow measurement that is swing between the rich and lean thresholds can also
not correct. Disconnect the MAF sensor to see it the cause this condition. Operate the vehicle by
rich condition is corrected. If so, replace the MAF monitoring the HO2S voltage with a Tech 2. If the
sensor. HO2S voltage is limited within a range between 300
D Check for a leak in the fuel pressure regulator mV to 600 mV, check the HO2S signal circuit wiring
diaphragm by checking the vacuum line to the and associated terminal conditions.
regulator for the presence of fuel. There should be no D If none of the above conditions are present, replace the
fuel in the vacuum line. affected HO2S.
D An intermittent TP sensor output will cause the system
to go rich due to a false indication of the engine Test Description
accelerating. Number(s) below refer to the step number(s) on the
D Shorted Heated Oxygen Sensor (HO2S) –If the HO2S Diagnostic Chart.
is internally shorted, the HO2S voltage displayed on
the Tech 2 will be over 1 volt. Try disconnecting the 3. DTC P0132 failing during “deceleration fuel cutoff
affected HO2S with the key “ON,” engine “OFF.” If the mode” operation may indicate a condition described
displayed HO2S voltage changes from over 1000 mV in the “Diagnostic Aids” above. If the DTC P0132
to around 450 mV, replace the HO2S. Silicon test passes while the Failure Records conditions are
contamination of the HO2S can also cause a high being duplicated, an intermittent condition is
HO2S voltage to be indicated. This condition is indicated.
indicated by a powdery deposit on the portion of the Reviewing the Failure Records vehicle mileage since the
HO2S exposed to the exhaust stream. If diagnostic test last failed may help determine how often
contamination is noticed, replace the affected HO2S.
the condition that caused the DTC to be set occurs. This
D Open HO2S Signal Circuit or Faulty HO2S–A poor may assist in diagnosing the condition.
connection or open in the HO2S signal circuit can
cause the DTC to set during deceleration fuel mode.
DTC P0132 – HO2S Circuit High Voltage Bank 1 Sensor 1

performed? System
3. Operate the vehicle within parameters specified
under “Conditions for Setting the DTC” included in 952 mV (500
Diagnostic Support.
mV in
4. Using a Tech 2, monitor Bank 1 HO2S 1 voltage. deceleration
Does the Bank 1 HO2S 1 voltage remain above the fuel cutoff
specified value? mode) Go to Step 4 Go to Step 3
3 1. Ignition “ON,” review and record Tech 2 Failure
Records data.
4. Note the test result. Refer to
2. Disconnect Bank 1 HO2S 1.
4. At HO2S Bank 1 Sensor 1 connector (PCM side)
use a DVM to measure voltages at the high and low
signal terminals.
Are the voltages in the specified range? 3-4 V Go to Step 5 Go to Step 6
5 Repair short to voltage in signal circuit.
DTC P0132 – HO2S Circuit High Voltage Bank 1 Sensor 1 (Cont'd)

6 1. Ignition “ON,” engine“OFF.”
2. At Bank 1 HO2S 1 connector (PCM side) jumper
both the HO2S high and low signal circuits (PCM
side) to ground.
Is Bank 1 HO2S 1 voltage below the specified value? 10 mV Go to Step 7 Go to Step 8
7 1. Disconnect the jumpers to ground from Bank 1
HO2S 1 PCM-side connector.
2. With the HO2S 1 connector disconnected, monitor
Bank 1 HO2S 1 voltage. Refer to
Is Bank 1 HO2S 1 voltage between the specified Diagnostic
values? 425-475 mV Aids Go to Step 8
8 Replace the PCM.
procedures.
Diagnostic Trouble Code (DTC) P0133 HO2S Slow Response Bank 1 Sensor 1
D06RY00170
Circuit Description D All above conditions are met for 3 seconds.

The powertrain control module (PCM) continuously D 90 seconds after “closed loop” has been enabled,
monitors the heated oxygen sensor (HO2S) activity for 90 Bank1 HO2S 1 average transition time between
300 mV and 600 mV is too slow. The lean-to-rich
seconds after “closed loop” has been enabled. During the average transition response time was longer than 94
monitoring period the PCM counts the number of times milliseconds or rich-to-lean average transition
that a rich-to-lean and lean-to-rich response is indicated response time was longer than 105 milliseconds.
and adds the amount of time it took to complete all
rich-to-lean transitions and lean-to-rich transitions. With Action Taken When the DTC Sets
this information, an average time for rich-to-lean and D The PCM will illuminate the malfunction indicator Lamp
lean-to-rich transitions can be determined. If the average (MIL) after the second consecutive trip in which the
response time of either transition is too slow, a DTC fault is detected.
P0133 will be set. D The PCM will store conditions which were present
A lean-to-rich transition is indicated when the HO2S when the DTC was set as Freeze Frame and in the
voltage changes from less than 300 mV to greater than Failure Records data.
600 mV. A rich-to-lean transition is indicated when the D “Open loop” fuel control will be in effect.
HO2S voltage changes from more than 600 mV to less
than 300 mV. An HO2S that responds too slowly is likely Conditions for Clearing the MIL/DTC
to be faulty and should be replaced. D The PCM will turn the MIL “OFF” on the third
Conditions for Setting the DTC been run and the fault condition is no longer present.
D No related DTCs. D A history DTC P0133 will clear after 40 consecutive
D Engine coolant temperature (ETC) is above 50°C warm-up cycles have occurred without a fault.
(122°F) for automatic transmission; 75°C (167°F) for D DTC P0133 can be cleared by using the Tech 2 “Clear
manual transmission. Info” function or by disconnecting the PCM battery
D Engine is operating in “closed loop.” feed.
D Engine has been running for at least 1 minute. Diagnostic Aids
D Engine speed is between 1500 RPM and 3000 RPM.
D Canister purge duty cycle is greater than 2%.
D Mass air flow is between 9 g/second and 42 g/second. for backed-out terminals, improper mating, broken
Bank 1 HO2S 1 display on the Tech 2 while moving
connectors and wiring harnesses related to the sensor.
A change in the display will indicate the location of the
fault.
If DTC P0133 cannot be duplicated, reviewing the Failure
Records vehicle mileage since the diagnostic test last
failed may help determine how often the condition that
caused the DTC to be set occurs. This may assist in
diagnosing the condition.
Test Description
Diagnostic Chart.
2. Verifies that the fault is currently present.
3. HO2S transition time, ratio mean volts and switching
DTCs set for multiple sensors indicate probable
contamination. Before replacing the sensors,
isolate and correct the source of the contamination
to avoid damaging the replacement sensors.
DTC P0133 – HO2S Slow Response Bank 1 Sensor 1

performed? System
2 NOTE: If any DTCs are set (expect P0153, P1133,
P1134, P1153, and/or P1154), refer to those DTCs
before proceeding with this diagnostic chart.
2. Idle the engine at operating temperature.
under “Conditions for Setting the DTC” included in
Diagnostic Support.
3 Did the Tech 2 also indicate DTC P0153, P1133,
P1134, P1153, and/or P1154 failed this ignition? — Go to Step 17 Go to Step 4
4 Check for leaks at the pipe joints.
Are the joints leaking? — Go to Step 5 Go to Step 6
5 Tighten the U–bolt nuts at the leaking joints.
6 Check for gaskets that are damaged or improperly
installed.
Are there damaged or misaligned gaskets? — Go to Step 7 Go to Step 8
7 1. Replace damaged gaskets.
2. Align the connections.
3. Tighten the connections.
8 Check for loose exhaust flange connections.
Are the flange connections loose? — Go to Step 2 Go to Step 10
9 Tighten the stud nuts or bolts to specifications.
10 Check for burned or corroded exhaust pipes.
Are the exhaust pipes burned or corroded? — Go to Step 11 Go to Step 12
11 Replace the exhaust pipes, as required.
12 Check for leaks at the exhaust manifold.
Are there leaks at the exhaust manifold? — Go to Step 13 Go to Step 14
13 Tighten the bolts to specifications to replace the
manifold if necessary.
DTC P0133 – HO2S Slow Response Bank 1 Sensor 1 (Cont'd)

14 Visually/physically inspect the following items:
D Ensure that the Bank 1 HO2S 1 is securely
installed.
D Check for corrosion on terminals.
D Check terminal tension (at Bank 1 HO2S 1 and at
the PCM).
D Check for damaged wiring.
Was a problem found in any of the above areas? — Go to Step 18 Go to Step 15
15 1. Disconnect Bank 1 HO2S 1.
3. Using a DVM at the PCM side of the HO2S 1
connector, measure the voltage between the high
signal circuit and ground. Also measure the voltage
between the low signal circuit and ground.
Are both voltages in the specified range? 3-4 V Go to Step 16 Go to Step 19
16 1. With Bank 1 HO2S 1 disconnected, jumper the high
and low (PCM side) signal circuits to ground.
3. Using a Tech 2, monitor the Bank 1 HO2S 1 voltage.
Does the Tech 2 indicate less than 10 mV and
immediately return to about 450 mV when the jumper is
removed? — Go to Step 21 Go to Step 22
17 Replace the affected heated oxygen sensors.
NOTE: Before replacing sensors, the cause of the
contamination must be determined and corrected.
D Fuel contamination.
D Use of improper RTV sealant.
D Engine oil/coolant consumption.
18 Repair condition as necessary.
19 Check for faulty PCM connections or terminal damage.
20 Repair open, short or grounded signal circuit.
21 Replace Bank 1 HO2S 1.
22 Replace the PCM.
procedures.

P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1
D06RY00171
Circuit Description D Oxygen sensor heater has been determined to be

functioning properly.
D The powertrain control module (PCM) supplies a bias
voltage of about 450 mV between the heated oxygen D Bank 1 HO2S 1 signal voltage remains between
sensor (HO2S) high and low circuits. When measured 400 mV and 500 mV for a total of 77 seconds over a
with a 10 megaohm digital voltmeter, this may display 90-second period of time.
as low as 320 mV. The oxygen sensor varies the
voltage within a range of about 1000 mV when the Action Take When the DTC Sets
exhaust is rich, down through about 10 mV when D The PCM will illuminate the malfunction indicator lamp
exhaust is lean. The PCM constantly monitors the (MIL) the first time the fault is detected.
HO2S signal during “closed loop” operation and
compensates for a rich or lean condition by decreasing D The PCM will store conditions which were present
or increasing injector pulse width as necessary. If the when the DTC was set as Freeze Frame and in the
Bank 1 HO2S 1 voltage remains at or near the 450 mV Failure Records data.
bias for an extended period of time, DTC P0134 will be D “Open loop” fuel control will be in effect.
set, indicating an open sensor signal or sensor low
circuit. Conditions for Clearing the MIL/DTC
D Heated oxygen sensors are used to minimize the D The PCM will turn the MIL “OFF” on the third
amount of time required for “closed loop” fuel control consecutive trip cycle during which the diagnostic has
operation and to allow accurate catalyst monitoring. been run and the fault condition is no longer present.
The oxygen sensor heater greatly decreases the
amount of time required for fuel control sensors Bank D A history DTC P0134 will clear after 40 consecutive
1 HO2S 1 and Bank 2 HO2S 1 to become active. warm-up cycles have occurred without a fault.
D Oxygen sensor heaters are required by post-catalyst D DTC P0134 can be cleared by using the Tech 2 “Clear
monitor sensors to maintain a sufficiently high Info” function or by disconnecting the PCM battery
temperature for accurate exhaust oxygen content feed.
readings further from the engine.
Diagnostic Aids
Conditions for Setting the DTC Check for the following conditions:
D No related DTCs. D Poor connection or damaged harness – Inspect the
harness connectors for backed-out terminals,
D Battery voltage is above 10 volts. improper mating, broken locks, improperly formed or
D Engine run time is longer than 40 seconds.
damaged terminals, poor terminal-to-wire connection, and related connectors. If the fault is induced, the
and damaged harness. HO2S signal voltage will change. This may help isolate
D Faulty HO2S heater or heater circuit – With the ignition the location of the malfunction.
“ON,” engine “OFF,” after a cool down period, the
HO2S 1 voltage displayed on the Tech 2 is normally Test Description
455-460 mV. A reading over 1000 mV indicates a Number(s) below refer to the step number(s) on the
signal line shorted to voltage. A reading under 5 mV Diagnostic Chart.
indicates a signal line shorted to ground or signal lines
shorted together. Disconnect the HO2S and connect 3. If the DTC P0134 test passes while the Failure
a test light between the HO2S ignition feed and heater Records conditions are being duplicated, an
ground circuits. If the test light does not light for 2 intermittent conditions is indicated.
seconds when the ignition is turned on, repair the open Reviewing the Failure Records vehicle mileage since the
ignition feed or sensor ground circuit as necessary. If diagnostic test last failed may help determine how often
the test light lights and the HO2S signal and low circuits
are OK, replace the HO2S. the condition that caused the DTC to be set occurs. This
may assist in diagnosing the condition.
D Intermittent test – With the Ignition “ON,” monitor the
HO2S signal voltage while moving the wiring harness
DTC P0134 –HO2S Circuit Insufficient Activity Bank 1 Sensor 1

performed? System
3. Operate the engine above 1200 RPM for two
minutes.
Does the Tech 2 indicate Bank 1 HO2S 1 voltage
varying outside the specified values? 400-500 mV Go to Step 3 Go to Step 4
4 Check for a damaged harness.
5 Check for poor Bank 1 HO2S 1 high and low circuit
terminal connections at the Bank 1 HO2S 1 harness
connector and replace terminal(s) if necessary.
terminal connections at the PCM and replace terminals
if necessary.
2. With the PCM disconnected, check continuity of the
Bank 1 HO2S 1 high circuit.
3. If the Bank 1 HO2S 1 high circuit measures over 5.0
ohms, repair open or poor connection as necessary.
Was a Bank 1 HO2S 1 high circuit problem found and
corrected? — Verify repair Go to Step 8
DTC P0134 –HO2S Circuit Insufficient Activity Bank 1 Sensor 1 (Cont'd)

Bank 1 HO2S 1 low circuit.
3. If the Bank 1 HO2S 1 low circuit measures over 5
Was a Bank 1 HO2S 1 low circuit problem found and
2. Disconnect Bank 1 HO2S 1 and jumper the HO2S
high and low circuits (PCM side) to ground.
Is Bank 1 HO2S 1 voltage in the specified range? 0-10 mV Go to Step 10 Go to Step 11
11 Replace the PCM.
procedures.
Diagnostic Trouble Code (DTC) P0135 HO2S Heater Circuit Bank 1 Sensor 1
D06RY00171
Circuit Description D Engine coolant temperature (ECT) is less than 32°C

(90°F) at start-up.
of time required for “closed loop” fuel control operation D IAT and ECT are within 6°C (11°F) of each other at
start-up.
and to allow accurate catalyst monitoring. The oxygen
sensor heater greatly decreases the amount of time D Ignition voltage is between 11 and 18 V.
required for fuel control sensors Bank 1 HO2S 1 and Bank D Average mass air flow is less than 21 g/second during
2 HO2S 1 to become active. Oxygen sensor heaters are sample period.
required by post-catalyst monitor sensors to maintain a D Bank 1 HO2S 1 voltage does not change more than
sufficiently high temperature which allows accurate 150 mV from the bias voltage (between 400 mV and
500 mV) for a longer amount of time than it should. The
exhaust oxygen content readings further from the engine. maximum amount of time to come up to operating
The powertrain control module (PCM) will run the heater range is 150 seconds. This warm-up time depends on
test only after a cold start (determined by engine coolant the engine coolant temperature at start-up and
and intake air temperature at the time of start-up) and only accumulate air flow since start-up.
once during an ignition cycle. When the engine is started
the PCM will monitor the HO2S voltage. When the HO2S Action Taken When the DTC Sets
voltage indicates a sufficiently active sensor, the PCM D The PCM will illuminate the malfunction indicator lamp
looks at how much time has elapsed since start-up. If the (MIL) after the second consecutive trip in which the
PCM determines that too much time was required for the fault is detected.
Bank 1 HO2S 1 to become active, a DTC P0135 will set. D The PCM will store conditions which were present
The time it should take the HO2S to reach operating when the DTC was set as Freeze Frame and in the
temperature is based on the accumulated amount of air Failure Records data.
that has passed through the MAF sensor and into the
engine (more accumulated air flow = shorter time to Conditions for Clearing the MIL/DTC
HO2S activity). D The PCM will turn the MIL “OFF” on the third
D Intake air temperature (IAT) is less than 32°C (90°F)
at start-up.
D DTC P0135 can be cleared by using the Tech 2 “Clear Test Description
feed. Number(s) below refer to the step number(s) on the
Diagnostic Chart.
Diagnostic Aids 2. The HO2S should be allowed to cool before
Check for the following conditions: performing this test. If the HO2S heater is
functioning, the signal voltage will gradually increase
for backed-out terminals, improper mating, broken or decrease as the sensor element warms. If the
locks, improperly formed or damaged terminals, and heater is not functioning, the HO2S signal will
poor terminal-to-wire connection. remain near the 450 mV bias voltage.
D Damaged harness – Inspect the wiring harness for 4. Ensures that the ignition feed circuit to the HO2S is
damage. If the harness appears to be OK, observe the not open or shorted. The test light should be
ECT display on the Tech 2 while moving connectors connected to a good chassis ground, in case the
and wiring harnesses related to the sensor. A change HO2S low or HO2S heater ground circuit is faulty.
Reviewing the Failure Records vehicle mileage since the 5. Checks the HO2S heater ground circuit.
diagnostic test last failed may help determine how often 6. Checks or an open or shorted HO2S heater element.
the condition that caused the DTC to be set occurs. This 10.An open HO2S signal or low circuit can cause the
may assist in diagnosing the condition. HO2S heater to appear faulty. Check these circuits
before replacing the sensor.
DTC P0135 – HO2S Heater Circuit Bank 1 Sensor 1

performed? System
2 NOTE: If the engine has just been operating ,allow the
engine to cool for at least 15 minutes before
proceeding.
2. Connect a fused jumper at the fuel pump relay
socket, between the battery positive at the relay and
the relay wire that leads to the fuel pump and HO2S
fuses.
4. Install a Tech 2.
6. Monitor the Bank 1 HO2S 1 voltage for several Above
minutes. 650 mV or Refer to
Did the HO2S voltage go from bias voltage to above or below Diagnostic
below the specified values? 250 mV Aids Go to Step 3
3 Inspect the fuse for the Bank 1 HO2S 1 ignition feed.
Is the fuse open? — Go to Step 15 Go to Step 4
2. Raise the vehicle.
3. Disconnect the Bank 1 HO2S 1 electrical connector.
4. Using a test light connected to a good ground (do
not use Bank 1 HO2S 1 heater ground or Bank 1
HO2S 1 low), probe the ignition feed circuit at the
Bank 1 HO2S 1 electrical connector (PCM harness
side).
5 Connect the test light between the Bank 1 HO2S 1
ignition feed and the Bank 1 HO2S 1 heater ground.
DTC P0135 – HO2S Heater Circuit Bank 1 Sensor 1 (Cont'd)

6 1. Allow the HO2S to cool for at least 15 minutes.
2. Using a DVM, measure the resistance between the
Bank 1 HO2S 1 ignition feed and the Bank 1 HO2S 1
heater ground at the Bank 1 HO2S 1 pigtail.
Is the HO2S heater resistance within the specified
values? 3-6 ohms Go to Step 9 Go to Step 10
7 Repair the open Bank 1 HO2S 1 ignition feed circuit to
Bank 1 HO2S 1.
8 Repair the open Bank 1 HO2S 1 heater ground circuit
to Bank 1 HO2S 1.
9 1. Check for a poor connection at the Bank 1 HO2S 1
harness terminals.
2. If a poor connection is found, replace terminals.
10 Check for a poor Bank 1 HO2S 1 high or low circuit
terminal connection at the Bank 1 HO2S 1 harness
2. Disconnect the PCM and check the continuity of the
Bank 1 HO2S 1 signal circuit and the Bank 1 HO2S
1 low circuit.
3. If the Bank 1 HO2S 1 high circuit or HO2S low circuit
measures over 5 ohms, repair open or poor
connection as necessary.
12 Check for a poor Bank 1 HO2S 1 low circuit terminal
connection at the PCM and replace the terminal if
necessary.
13 Check for a poor Bank 1 HO2S 1 high circuit terminal
necessary.
14 Replace the Bank 1 HO2S 1.
15 Locate and repair the short to ground in Bank 1 HO2S 1
ignition feed circuit and replace the fault fuse.

D06RY00172
Circuit Description D Bank 1 HO2S 2 signal voltage remains below 400 mV

during power enrichment mode fuel control operation
The powertrain control module (PCM) supplies bias for up to 5 seconds.
voltage of about 450 mV between the heated oxygen
sensor (HO2S) signal high and signal low circuits. When Action Taken When the DTC Sets
measured with a 10 megaohm impedance digital
voltmeter, this may display as low as 350 mV. The D The PCM will illuminate the malfunction indicator lamp
oxygen sensor varies the voltage within a range of about
1000 mV when exhaust is rich, down through about D The PCM will store conditions which were present
when the DTC set as Freeze Frame and in the Failure
10 mV when the exhaust is lean. The PCM constantly Records data.
monitors the HO2S signal during “closed loop” operation
and compensates for a rich or lean condition by Conditions for Clearing the MIL/DTC
decreasing or increasing injector pulse width as
D The PCM will turn the MIL “OFF” on the third
necessary. If the Bank 1 HO2S 2 signal voltage remains consecutive trip cycle during which the diagnostic has
excessively low for an extended period of time, DTC been run and the fault condition is no longer present.
P0137 will be set. D A history DTC P0137 will clear after 40 consecutive
D No related DTCs. Info” function or by disconnecting the PCM battery
D Engine is operating in “closed loop.” feed.
D Engine coolant temperature is above 60°C (140°F).
Diagnostic Aids
D “Closed loop” commanded air/fuel ratio is between
14.5 and 14.8. Check for the following conditions:
D Throttle angle is between 3% and 19%. D Heated oxygen sensor wiring – The sensor pigtail may
be mispositioned and contacting the exhaust system.
D Bank 1 HO2S 2 signal voltage remains below 22 mV
during normal “closed loop” operation for a total of 106 D Poor PCM to engine grounds.
seconds over a 125-second period of time. D Fuel pressure – A condition which causes a lean
OR exhaust can cause DTC P0137 to set. The system will
go lean if pressure is too low. The PCM can
compensate for some decrease. However, if fuel alcohol in the fuel can also cause this condition. Refer
pressure is too low, a DTC P0137 may be set. Refer to Fuel System Diagnosis for procedure to check for
to Fuel System Diagnosis. fuel contamination.
D Lean injector(s) – Perform “Injector Balance Test.” D If none of the above conditions are present, replace the
D Vacuum leaks – Check for disconnected or damaged affected HO2S.
vacuum hoses and for vacuum leaks at the intake
manifold, throttle body, EGR system, and PCV system. Test Description
D Exhaust leaks – An exhaust leak may cause outside air Number(s) below refer to the step number(s) on the
to be pulled into the exhaust gas stream past the Diagnostic Chart.
HO2S, causing the DTC P0137 to set. Check for 3. DTC P0137 failing during operation may indicate a
exhaust leaks near the Bank 1 HO2S 2 sensor.
condition described in the “Diagnostic Aids” above.
D MAF sensor – The system can go lean if the MAF If the DTC0137 test passes while the Failure
sensor signal indicates an engine airflow
sensor to see if the lean condition is corrected. If so, intermittent condition is indicated.
DTC P0137 –HO2S Circuit Low Voltage Bank 1 Sensor 2

performed? System
Does the Bank 1 HO2S voltage remain below the
4 1. Turn ignition “OFF.”
3. Check the Bank 1 HO2S 2 high and low signal
circuits for a short to ground or a short to the heater
ground circuit.
Were Bank 1 HO2S 2 signal circuits shorted? — Go to Step 5 Go to Step 6
2. Leave the PCM and HO2S 2 disconnected.
signal circuits.
DTC P0137 –HO2S Circuit Low Voltage Bank 1 Sensor 2 (Cont'd)

2. Reconnect the PCM, leave HO2S 2 disconnected.
Does the Tech 2 indicate Bank 1 HO2S 2 voltage near Diagnostic
the specified value? 425-475 mV Aids Go to Step 9
9 Replace the PCM.
procedures.

D06RY00172
Circuit Description D Bank 1 HO2S 2 signal voltage remains above 500 mV

during deceleration fuel cut–off mode operation for up
The powertrain control module (PCM) supplies bias to 3 seconds.
voltage of about 450 mV between the heated oxygen
sensor (HO2S) signal high and signal low circuits. When Action Taken When the DTC Sets
measured with a 10 megaohm digital voltmeter, this may
display as low as 320 mV. The oxygen sensor varies the D The PCM will illuminate the malfunction indicator lamp
voltage within a range of about 1000 mV when exhaust is
rich, down through about 10 mV when the exhaust is D The PCM will store conditions which were present
lean. The PCM constantly monitors the HO2S signal Failure Records data.
during “closed loop” operation and compensates for a rich
or lean condition by decreasing or increasing injector Conditions for Clearing the MIL/DTC
pulse width as necessary. If the Bank 1 HO2S 2 voltage
remains excessively high for an extended period of time, consecutive trip cycle during which the diagnostic has
DTC P0138 will be set. been run and the fault condition is no longer present.
Conditions for Setting the DTC warm-up cycles have occurred without a fault.
D No related DTCs. D DTC P0138 can be cleared by using the Tech 2 “Clear
D Engine is operating in “closed loop.” Info” function or by disconnecting the PCM battery
D “Closed loop” commanded air/fuel ratio is between feed.
14.5 and 14.8.
Diagnostic Aids
D Throttle angle is between 3% and 19%. Check for the following conditions:
D Bank 1 HO2S 2 signal voltage remains above 952 mV D Fuel pressure – An excessively rich fuel mixture can
during normal “closed loop” operation for a total of 106 cause a DTC P0138 to be set. Refer to Fuel System
seconds over a 125-second period of time. Diagnosis.
OR D Rich injector(s) – Perform “Injector Balance Test.”
D Leaking injector – Refer to Fuel System Diagnosis.
D Evaporative emissions (EVAP) canister purge – Check D Open HO2S Signal Circuit of Faulty HO2S – A poor
for fuel saturation. If full of fuel, check the canister connection or open in the HO2S signal circuit can
control and hoses. Refer to Evaporative Emission cause the DTC to set during deceleration fuel mode.
(EVAP) Control System. An HO2S which is faulty and not allowing a full voltage
D MAF sensor –The system can go rich if the MAF swing between the rich and lean thresholds can also
sensor signal indicates an engine airflow cause this condition. Operate the vehicle while
measurement that is not correct. Disconnect the MAF monitoring the HO2S voltage with a Tech 2. If the
sensor to see if the rich condition is corrected. If so, HO2S voltage is limited within a range between
replace the MAF sensor. 300 mV to 600 mV, check the HO2S signal and wiring
and associated terminal connections.
D Check for a leak in fuel pressure regulator diaphragm
by checking the vacuum line to the regulator for the D If none of the above conditions are present, replace the
presence of fuel. There should be no fuel in the affected HO2S.
vacuum line.
D TP sensor – An intermittent TP sensor output will Test Description
cause the system to go rich, due to a false indication Number(s) below refer to the step number(s) on the
of the engine accelerating. Diagnostic Chart.
D Shorted Heated Oxygen Sensor (HO2S) – If the HO2S 3. DTC P0138 being set during deceleration fuel mode
is internally shorted the HO2S voltage displayed on the operation may indicate a condition described in the
Tech 2 will be over 1 volt. Try disconnecting the “Diagnostic Aids” above. If the DTC P0138 test
affected HO2S with the key “ON,” engine “OFF.” If the
displayed HO2S voltage changes from over 1000 mV passes while the Failure Records conditions are
to around 450 mV, replace the HO2S. Silicon being duplicated, an intermittent condition is
contamination of the HO2S can also cause a high indicated.
HO2S voltage to be indicated. This condition is Reviewing the Failure Records vehicle mileage since the
indicated by a powdery deposit on the portion of the diagnostic test last failed may help determine how often
HO2S exposed to the exhaust stream. If the condition that caused the DTC to be set occurs. This
contamination is noticed, replace the affected HO2S. may assist in diagnosing the condition.

performed? System
under “Conditions for Setting the DTC” criteria 952 mV
(500 mV in
Does the Bank 1 HO2S voltage remain above the fuel cutoff
3 1. Ignition “ON,” review and record Tech 2 Failure
Records data.
4. At the HO2S Bank 1 Sensor 2 connector (PCM
side), use a DVM to measure voltages at the high
and low signal terminals.
Are the voltages above the specified range? 3-4 V Go to Step 5 Go to Step 6

5 Repair short to voltage in the signal circuit.
side) to ground.
HO2S 2 PCM–side connector.
BANK 1 HO2S 2 voltage. Refer to
Is the Bank 1 HO2S 2 voltage between the specified Diagnostic
8 Replace the PCM.
procedures.

D06RY00173
Circuit Description maintain a sufficiently high temperature for accurate

To control emissions of hydrocarbons (HC), carbon exhaust oxygen content readings further from the engine.
monoxide (CO), and oxides of nitrogen (NOx), a
three-way catalytic converter is used. The catalyst within
the converter promotes a chemical reaction which D No related DTCs.
oxidizes the HC and CO present in the exhaust gas, D Battery voltage is above 10 volts.
converting them into harmless water vapor and carbon D Engine run time is longer than 40 seconds.
dioxide. The catalyst also reduces NOx, converting it to D Oxygen sensor heater is functioning properly.
nitrogen. The powertrain control module (PCM) has the D Engine is operating in “closed loop”
ability to monitor this process using the Bank 1 HO2S 1
D Bank 1 HO2S 2 signal voltage remains between
and the Bank 1 HO2S 2 heated oxygen sensors. The 426 mV and 474 mV for a total of 106 seconds over a
Bank 1 HO2S 2 sensor produces an output signal which 125-second period of time.
indicates the amount of oxygen present in the exhaust
gas entering the three-way catalytic converter. The Bank Action Taken When the DTC Sets
1 HO2S 2 sensor produces an output signal which D The PCM will illuminate the malfunction indicator lamp
indicates the oxygen storage capacity of the catalyst; this (MIL) the first time the fault is detected.
in turn indicates the catalyst’s ability to convert exhaust D The PCM will store conditions which were present
gases efficiently. If catalyst is operating efficiently, the when the DTC was set as Freeze Frame and in the
Bank 1 HO2S 1 signal will be far more active than that Failure Records data.
produced by the Bank 1 HO2S 2 sensor. If the Bank 1
HO2S 2 signal voltage remains between 400 mV and Conditions for Cleaning the MIL/DTC
500 mV for an extended period of time, DTC P0140 will be D The PCM will turn the MIL “OFF” on the third
set. Heated oxygen sensors are used to minimize the consecutive trip cycle during which the diagnostic has
amount of time required for “closed loop” fuel control been run and the fault condition is no longer present.
operation and to allow accurate catalyst monitoring. The D A history DTC P0140 will clear after 40 consecutive
oxygen sensor heater greatly decreases the amount of warm-up cycles have occurred without a fault.
time required for fuel control sensors Bank 1 HO2S 1 and D DTC P0140 can be cleared by using the Tech 2 “Clear
Bank 2 HO2S 1 to become active. Oxygen sensor Info” function or by disconnecting the PCM battery
heaters are required by post-catalyst monitor sensors to feed.
Diagnostic Aids D Intermittent test–With the ignition “ON,” monitor the
Check for the following conditions: and related connectors. If the fault is induced, the
D Poor connection or damaged harness– Inspect the HO2S signal voltage will change. This may help isolate
harness connectors for backed-out terminals, the location of the malfunction.
improper mating, broken locks, improperly formed or
damaged terminals, poor terminal-to-wire connection, Test Description
and damaged harness.
Number (s) below refer to the step number (s) on the
D Faulty HO2S heater or heater circuit–With the
ignition“ON,” engine “OFF,” the HO2S voltage Diagnostic Chart.
displayed on a Tech 2 should gradually drop to below 3. If the DTC P0140 test passes while the Failure
250 mV. If not, disconnect the HO2S and connect a Records conditions are being duplicated, an
test light between the HO2S ignition feed and heater intermittent condition is indicated.
ground circuits. If the test light does not light, repair the Reviewing the Failure Records vehicle mileage since the
open ignition feed or sensor ground circuit as
necessary. If the test light lights and the HO2S signal diagnostic test last failed may help determine how often
and low circuits are OK, replace the HO2S. the condition that caused the DTC to be set occurs. This
DTC P0140 – HO2S Circuit Insufficient Activity BANK 1 SENSOR 2

performed? System
minutes.
terminal connections at the PCM and replace
DTC P0140 – HO2S Circuit Insufficient Activity BANK 1 SENSOR 2 (Cont'd)

3. If the Bank 1 HO2S 2 low circuit measures over 5.0
11 Replace the PCM.
procedures.
D06RY00173

of time required for closed loop fuel control operation and D IAT and ECT are within 6°C (11°F) of each other at
start-up.
to allow accurate catalyst monitoring. The oxygen sensor
heater greatly decreases the amount of time required for D Ignition voltage is between 11 volts and 18 volts.
fuel control sensors Bank 1 HO2S 1 and Bank 2 HO2S 1 D Average mass airflow is less than 23 g/second during
to become active. Oxygen sensor heaters are required the sample period.
by post-catalyst monitor sensors to maintain a sufficiently D Bank 1 HO2S 2 voltage does not change more than
high temperature which allows accurate exhaust oxygen 150 mV from the bias voltage (between
400 mV–500 mV) for a longer amount of time than it
content readings further from the engine. should. The maximum amount of time to come up to
The powertrain control module (PCM) will run the heater operating range is 120 seconds. This warm-up time
test only after a cold start (determined by engine coolant depends on the engine coolant temperature at start-up
and intake air temperature at the time of start-up) and only and accumulated air flow since start-up.
the PCM will monitor the HO2S voltage. When the Bank Action Taken When the DTC Sets
HO2S voltage indicates a sufficiently active sensor, the D The PCM will illuminate the malfunction indicator lamp
PCM looks at how much time has elapsed since start-up. (MIL) after the second consecutive trip in which the
If the PCM determines that too much time was required fault is detected.
for the Bank 1 HO2S 2 to become active, a DTC P0141 D The PCM will store conditions which were present
will set. The time it should take the HO2S to reach when the DTC was set as Freeze Frame and in the
operating temperature is based on the total amount of air Failure Records data.
engine (more total airflow = shorter time to HO2S Conditions for Clearing the MIL/DTC
activity). D The PCM will turn the MIL “OFF” on the third
at start-up.
D DTC P0141 can be cleared by using the Tech 2 “Clear 2. The HO2S should be allowed to cool before
Info” function or by disconnecting the PCM battery performing this test. If the HO2S heater is
feed. functioning, the signal voltage will gradually increase
or decrease as the sensor element warms. If the
Diagnostic Aids heater is not functioning, the HO2S signal will
Check for the following conditions: remain near the 450 mV bias voltage.
D Poor connection at PCM – Inspect harness connectors 4. This ensures that the ignition feed circuit to the
for backed-out terminals, improper mating, broken HO2S is not open or shorted. The test light should
locks, improperly formed or damaged terminals, and be connected to a good chassis ground, in case the
poor terminal-to-wire connection. HO2S low or HO2S heater ground circuit is faulty.
damage. If the harness appears to be OK, observe the 5. This checks the HO2S heater ground circuit.
display on the Tech 2 while moving connectors and 6. This checks for an open or shorted HO2S heater
wiring harnesses related to the sensor. A change in the element.
display will indicate the location of the fault.
Reviewing the Failure Records vehicle mileage since the 11.An open HO2S signal or low circuit can cause the
diagnostic test last failed may help determine how often HO2S heater to appear faulty. Check these circuits
Test Description
Diagnostic Chart.

performed? System
2 NOTE: If the engine has just been operating, allow the
proceeding.
fuses.
3 Inspect the fuse for Bank 1 HO2S 2 ignition feed.
4. Using a test light connected to a good ground (do
not use Bank 1 HO2S 2 heater ground or Bank 1
side).

2. Using a DVM, measure the resistance between the
Is the HO2S resistance within the specified values? 3-6 ohms Go to Step 9 Go to Step 10
Bank 1 HO2S 2.
8 Repair the open Bank 1 HO2S 2 heater ground circuit.
harness terminals.
2. If a poor connection is found, replace the terminals.
2 low circuit.
3. If the Bank 1 HO2S 2 signal circuit or the HO2S low
circuit measures over 5 ohms, repair the open or
poor connection as necessary.
1 low circuit.
3. If the Bank 1 HO2S 1 high circuit or the HO2S low
necessary.
necessary.
15 Locate and repair the short to ground in Bank 1 HO2S 2
ignition feed circuit and replace the faulty fuse.

D06RY00174

or lean condition by decreasing or increasing injector consecutive trip cycle during which the diagnostic has
remains excessively low for an extended period of time, D A history DTC P0151 will clear after 40 consecutive
feed.
D No related DTCs.
D The engine is operating in “closed loop.” Diagnostic Aids
D Engine coolant temperature is above 60°C (140°F). Check for the following conditions:
D “Closed loop” commanded air/fuel ratio is between D Heated oxygen sensor wiring – The sensor pigtail may
14.5 and 14.8. be mispositioned and contacting the exhaust system.
D Throttle angle is between 3% and 19%. D Poor PCM to engine block grounds.
D Bank 2 HO2S 1 signal voltage remains below 22 mV D Fuel pressure – The system will go lean if pressure is
during normal “closed loop” operation for a total of 77 too low. The PCM can compensate for some
seconds over a 90-second period of time. decrease. However, if fuel pressure is too low, a DTC
P0151 may be set. Refer to Fuel System Diagnosis.
D Lean injector(s) – Perform “Injector Balance Test.”
D Vacuum leaks – Check for disconnected or damaged D If none of the above conditions are present, replace the
vacuum hoses and for vacuum leaks at the intake affected HO2S.
D Exhaust leaks – An exhaust leak may cause outside air Test Description
to be pulled into the exhaust gas stream past the Number(s) below refer to the step number(s) on the
HO2S, causing the system to appear lean. Check for Diagnostic Chart.
exhaust leaks that may cause a false lean condition to
be indicated. 3. DTC P0151 failing during operation may indicate a
D MAF sensor –The system can go lean if the MAF condition described in the “Diagnostic Aids” above.
sensor signal indicates an engine airflow If the DTC P0151 test passes while the Failure
sensor to see if the lean condition is corrected. If so, intermittent condition is indicate.
alcohol in the fuel can also cause this condition. Refer
to Fuel System Diagnosis for the procedure to check
for fuel contamination.
DTC P0151 – HO2S Circuit Low Voltage Bank 2 Sensor 1

performed? System
4. Note test result. Refer to
4 1. Turn ignition “OFF.”
ground circuit.
signal circuits.
DTC P0151 – HO2S Circuit Low Voltage Bank 2 Sensor 1 (Cont'd)

2. Reconnect the PCM, leave HO2S disconnected.
9 Replace the PCM.
procedures.

P0152 HO2S Circuit HIGH Voltage Bank 2 Sensor 1
D06RY00174

or lean condition by decreasing or increasing the injector consecutive trip cycle during which the diagnostic has
remains excessively high for an extended period of time, D A history DTC P0152 will clear after 40 consecutive
feed.
D No related DTCs.
D The engine is operating in “closed loop.” Diagnostic Aids
D The engine coolant temperature is above 60°C Check for the following conditions:
(140°F).
D Fuel pressure – The system will go rich if pressure is
D “Closed loop” commanded air/fuel ratio between 14.5 too high. The PCM can compensate for some
and 14.8. increase. However, if fuel pressure is too high, a DTC
D Bank 2 HO2S 1 signal voltage remains above 952 mV P0152 may be set. Refer to Fuel System Diagnosis.
during normal “closed loop” operation for a total of 77 D Rich injector(s) – Perform “Injector Balance Test.”
seconds over a 90-second period.
OR D Leaking injector – Refer to Fuel System Diagnosis.
D Bank 2 HO2S 1 signal voltage remains above 500 mV D Evaporative emissions (EVAP) system – Check the
during deceleration fuel cutoff mode operation for up to canister for fuel saturation. If the canister is full of fuel,
3 seconds. check EVAP control system components and hoses.
Refer to Evaporative Emission (EVAP) Control cause the DTC to set during deceleration fuel mode.
System. An HO2S which is faulty and not allowing a full voltage
D MAF sensor – The system can go rich if the MAF switch between the rich and lean thresholds can also
sensor signal indicates an engine airflow cause the condition. Operate the vehicle while
measurement that is not correct. Disconnect the MAF monitoring the HO2S voltage with a Tech 2. If the
sensor to see if rich condition is corrected. If so, HO2S is limited within a range between 300 mV to
replace MAF sensor. 600 mV, check the HO2S signal circuit wiring and
associated terminal connections.
D Check for leaking fuel pressure regulator diaphragm by
checking vacuum line to regulator for the presence of D If none of the above conditions are present, replace the
fuel. There should be no fuel in the vacuum line. affected HO2S.
D TP sensor – An intermittent TP sensor output will
cause the system to go rich, due to a false indication Test Description
of the engine accelerating. Number(s) below refer to the step number(s) on the
D Shorted Heated Oxygen Sensor (HO2S)– If the HO2S Diagnostic Chart.
is internally shorted, the HO2S voltage displayed on 3. DTC P0152 failing during deceleration fuel cutoff
the Tech 2 will be over 1 volt. Try disconnecting the mode operation may indicate a condition described
affected HO2S with the key “ON,” engine “OFF.” If the in the “Diagnostic Aids” above. If the DTC P0152
displayed HO2S voltage changes from over 1000 mV
to around 450 mV, replace the HO2S. Silicon test passes while the Failure Records conditions are
contamination of the HO2S can cause a high HO2S being duplicated, an intermittent condition is
voltage to be indicated. This condition is indicated by indicated.
powdery deposit on the portion of the HO2S exposed Reviewing the Failure Records vehicle mileage since the
to the exhaust stream. If contamination is noticed, diagnostic test last failed may help determine how often
replace the affected HO2S. the condition that caused the DTC to be set occurs. This
D Open HO2S Signal Circuit of Faulty HO2S– A poor may assist in diagnosing the condition.
connection or open in the HO2S signal circuit can

performed? System
2. Engine is at operating temperature.
(500 mV in
Does the Bank 2 HO2S 1 voltage remain above the fuel cut-off
4. At HO2S Bank 2 Sensor 1 connector (PCM side)
use a DVM to measure voltages at the high and low
signal terminals.

side) to ground.
Is the Bank 2 HO2S 1 voltage between the specified Diagnostic
8 Replace the PCM.
procedures.
Diagnostic Trouble Code (DTC) P0153 HO2S Slow Response Bank 2 Sensor 1
D06RY00174
Circuit Description D All above conditions are met for 3 seconds.

The powertrain control module (PCM) continuously D 90 seconds after “closed loop” has been enabled, Bank
monitors the heated oxygen sensor (HO2S) activity for 90 2 HO2S 1 average transition time between 300 mV
and 600 mV is too slow. The lean-to-rich average
seconds after “closed loop” has been enabled. During the transition response time was longer than 94
monitoring period the PCM counts the number of times milliseconds or the rich-to-lean average transition
that a rich-to-lean and lean-to-rich response is indicated response time was longer than 105 milliseconds.
and adds the amount of time it took to complete all
rich-to-lean transitions and lean-to-rich transitions. With Action Taken When the DTC Sets
this information, an average time for rich-to-lean and D The PCM will illuminate the malfunction indicator lamp
lean-to-rich transitions can be determined. If the average (MIL) after the second consecutive trip in which the
response time of either transition is too slow, a DTC fault is detected.
P0153 will be set. D The PCM will store conditions which were present
A lean-to-rich transition is indicated when the HO2S when the DTC set as Freeze Frame and in the Failure
voltage changes from less than 300 mV to greater than Records data.
600 mV. A rich-to-lean transition is indicated when the D “Open loop” fuel control will be in effect.
HO2S voltage changes from more than 600 mV to less
than 300 mV. An HO2S that responds too slowly is likely Conditions for Clearing the MIL/DTC
to be faulty and should be replaced. D The PCM will turn the MIL “OFF” on the third
D Engine coolant temperature (ECT) is above 50°C warm-up cycles have occurred without a fault.
(122°F) for automatic transmission; 75° (167°F) for D DTC P0153 can be cleared by using the Tech 2 “Clear
D The engine is operating in “closed loop.” feed.
D Engine has been running for at least one minute. Diagnostic Aids
D Canister purge duty cycle is above 2%.
D Mass air flow is between 9 g/second and 42 g/second. for backed-out terminals, improper mating, broken
connectors and wiring harnesses related to the sensor.
fault.
Reviewing the Failure Records vehicle mileage since the
diagnostic test last failed may help determine how often
Test Description
Diagnostic Chart.
2. Verifies that the fault is currently present.
3. HO2S transition time, ratio mean volts and switching
DTCs set for multiple sensors indicate probable
contamination. Before replacing the sensors,
isolate and correct the source of the contamination
to avoid damaging the replacement sensors.
DTC P0153 – HO2S Slow Response Bank 2 Sensor 1

performed? System
2 NOTE: If any DTCs are set, (except P0133, P1133,
P1134, P1153, and/or P1154), refer to those DTCs
before proceeding with this diagnostic chart.
3 Did the Tech 2 also indicate DTC P0153, P1133,
P1134, P1153, and/or P1154 test failed this ignition? — Go to Step 17 Go to Step 4
4 Check for leaks at the pipe joints.
5 Tighten the U-bolt nuts at the leaking joint.
Is your action complete? — Go to Step 2 —
6 Check for gaskets that are damage or improperly
installed.
7 1. Replace the damaged gaskets.
13 Tighten the bolts to specifications or replace the
DTC P0153 – HO2S Slow Response Bank 2 Sensor 1 (Cont'd)

14 1. Visually/physically inspect the following items:
installed.
D Check terminal tension (at Bank 2 HO2S 1 and
at the PCM).
signal circuit and ground.
Are both voltages in the specified range? 3-4 V Go to Step 16 Go to Step 19
NOTE: Before replacing the sensors, the cause of the
D Use of improper RV sealant.
22 Replace the PCM.
procedures.

D06RY00175
Circuit Description D Engine running time is longer than 40 seconds.

The powertrain control module (PCM) supplies a bias D Oxygen sensor heater is functioning properly.
voltage of about 450 mV between the heated oxygen D Bank 2 HO2S 1 signal voltage remains between
sensor (HO2S) high and low circuits. When measured 400 mV and 500 mV for a total of 77 seconds over a
with a 10 megaohm digital voltmeter, this may display as 90-second period of time.
low as 320 mV. The oxygen sensor varies the voltage
within a range of about 1000 mV when the exhaust is rich,
down through about 10 mV when exhaust is lean. The D The PCM will illuminate the malfunction indicator lamp
PCM constantly monitors the HO2S signal during “closed (MIL) the first time the fault is detected.
loop” operation and compensates for a rich or lean D The PCM will store conditions which were present
condition by decreasing or increasing injector pulse width when the DTC was set as Freeze Frame and in the
as necessary. If the Bank 2 HO2S 1 voltage remains at or
near the 450 mV bias for an extended period of time, DTC D “Open loop” fuel control will be in effect.
P0154 will be set, indicating an open sensor signal or
sensor low circuit.
Conditions for Clearing the MIL/DTC
Heated oxygen sensors are used to minimize the amount D The PCM will turn the MIL “OFF” on the third
of time required for “closed loop” fuel control operation consecutive trip cycle during which the diagnostic has
and to allow accurate catalyst monitoring. The oxygen been run and the fault condition is no longer present.
sensor heater greatly decreases the amount of time D A history DTC P0154 will clear after 40 consecutive
required for fuel control sensors Bank 1 HO2S 1 and Bank warm-up cycles have occurred without a fault.
2 HO2S 1 to become active. Oxygen sensor heaters are D DTC P0154 can be cleared by using the Tech 2 “Clear
required by post-catalyst monitor sensors to maintain a Info” function or by disconnecting the PCM battery
feed.
sufficiently high temperature for accurate exhaust oxygen
content readings further from the engine. Diagnostic Aids
D No related DTCs. harness connectors for backed-out terminals,
D Battery voltage is above 10 volts.
improper mating, broken locks, improperly formed or and related connectors. If the fault is induced, the
damaged terminals, poor terminal-to-wire-connection, HO2S signal voltage will change. This may help isolate
and damaged harness. the location of the malfunction.
D Faulty HO2S heater or heater circuit – With the ignition
“ON,” engine “OFF,” the HO2S 1 voltage displayed on Test Description
the Tech 2 is normally 455-460 mV. A reading over Number(s) below refer to the step number(s) on the
1000 mV indicates a signal line shorted to voltage. A Diagnostic Chart.
reading under 5 mV indicates a signal line shorted to
ground or signal lines shorted together. If not, 3. If the DTC P0154 test passes while the Failure
disconnect the HO2S and connect a test light between Records conditions are being duplicated, an
the HO2S ignition feed and heater ground circuits. If intermittent condition is indicated.
the test light does not light for 2 seconds when the Reviewing the Failure Records vehicle mileage since the
ignition is turned on, repair the open ignition feed or diagnostic test last failed may help determine how often
sensor ground circuit as necessary. If the test light
lights and the HO2S signal and low circuits are OK, the condition that caused the DTC to be set occurs. This
replace the HO2S. may assist in diagnosing the condition.
D Intermittent test – With the ignition “ON,” monitor the
DTC P0154 –HO2S Circuit Insufficient Activity Bank 2 Sensor 1

performed? System
minutes.
2. Review and record Tech 2 Failure Records data and
note parameters.
5 Check for a poor Bank 2 HO2S 1 high and low circuit
6 Check for a poor Bank 2 HO2S 1 high and low circuit
terminal connections at the PCM and replace
DTC P0154 –HO2S Circuit Insufficient Activity Bank 2 Sensor 1 (Cont'd)

3. If the Bank 2 HO2S 1 low circuit measures over 5.0
Is the Bank 2 HO2S 1 voltage in the specified range? 0-10 mV Go to Step 10 Go to Step 11
11 Replace the PCM.
procedures.
D06RY00175

of time required for closed loop fuel control operation and D IAT and ECT are within 6°C (11°F) of each other at
start-up.
to allow accurate catalyst monitoring. The oxygen sensor
heater greatly decreases the amount of time required for D Ignition voltage is between 11 volts and 18 volts.
fuel control sensors Bank 1 HO2S 1 and Bank 2 HO2S 1 D Average mass air flow for the sample period is less
to become active. Oxygen sensor heaters are required than 21 g/second.
by post-catalyst monitor sensors to maintain a sufficiently D Bank 1 HO2S 2 voltage does not change more than
high temperature which allows accurate exhaust oxygen 150 mV from the bias voltage (between
400 mV-500 mV) for a longer amount of time than it
content readings further from the engine. should. The maximum amount of time to come up to
the PCM will monitor the HO2S voltage. When the Bank Action Taken When the DTC Sets
HO2S voltage indicates a sufficiently active sensor, the D The PCM will illuminate the malfunction indicator lamp
that has passed through the mass air flow (MAF) sensor
and into the engine (more total air flow = shorter time to Conditions for Clearing the MIL/DTC
HO2S activity). D The PCM will turn the MIL “OFF” on the third
at start-up.
D DTC P0155 can be cleared by using the Tech 2 “Clear 2. The HO2S should be allowed to cool before
info” function or by disconnecting the PCM battery performing this test. If the HO2S heater is
feed. functioning, the signal voltage will gradually increase
or decrease as the sensor element warms. If the
Diagnostic Aids heater is not functioning, the HO2S signal will
Check for the following conditions: remain near the 450 mV bias voltage.
D Poor connection at PCM – Inspect harness connectors 4. Ensures that the ignition feed circuit to the HO2S is
for backed-out terminals, improper mating, broken not open or shorted. The test light should be
locks, improperly formed or damaged terminals, and connected to a good chassis ground, in case the
poor terminal-to-wire connection. HO2S low or HO2S heater ground circuit is faulty.
damage. If the harness appears to be OK, observe the 5. Checks the HO2S heater ground circuit.
display on the Tech 2 while moving connectors and 6. Checks for an open or shorted HO2S heater
wiring harnesses related to the sensor. A change in the element.
Reviewing the Failure Records vehicle mileage since the 10.An open HO2S signal or low circuit can cause the
diagnostic test last failed may help determine how often HO2S heater to appear faulty. Check these circuits
Test Description
Diagnostic Chart.

performed? System
proceeding.
fuses.
below the specified value? 250 mV Aids Go to Step 3
4. Using a test light connected to a known good ground
(do not use Bank 2 HO2S 1 heater ground or Bank 2
side).

5 Connect the test light between Bank 2 HO2S 1 ignition
feed and Bank 2 HO2S 1 heater ground.
2. Using a DVM, measure resistance between the
Bank 2 HO2S 1.
harness terminals.
2. If a poor connection is found, replace terminals.
10 Check for a poor Bank 2 HO2S 1 signal or low circuit
terminal connection at the Bank 2 HO2S 1 harness
1 low circuit.
3. If the Bank 2 HO2S 1 signal circuit or HO2S low
circuit measures over 5 ohms, repair open or poor
connection as necessary.
necessary.
13 Check for a poor Bank 2 HO2S 1 signal circuit terminal
necessary.
15 Locate and repair short to ground in Bank 2 HO2S 1
ignition feed circuit and replace the faulty fuse.

D06RY00176
Circuit Description D “Closed loop” commanded air/fuel ratio is between

14.5 and 14.8
To control emissions of hydrocarbons (HC), carbon
monoxide (CO), and oxides of nitrogen (NOx), a D Bank 2 HO2S 2 signal voltage remains below 22 mV
during normal “closed loop” operation for a total of 106
three-way catalytic converter is used. The catalyst within seconds over a 125-second period of time.
the converter promotes a chemical reaction which OR
oxidizes the HC and CO present in the exhaust gas,
D Bank 2 HO2S 2 signal voltage remains below 400 mV
converting them into harmless water vapor and carbon during “power enrichment” mode fuel control operation
dioxide. The catalyst also reduces NOx, converting it to for up to 5 seconds.
nitrogen. The powertrain control module (PCM) has the
ability to monitor this process using the Bank 2 HO2S 1 Action Taken When the DTC Sets
and the Bank 2 HO2S 2 heated oxygen sensors. The
Bank 2 HO2S 1 sensor produces an output signal which (MIL) the first time the fault is detected.
indicates the amount of oxygen present in the exhaust D The PCM will store conditions which were present
gas entering the three-way catalytic converter. The Bank when the DTC was set as Freeze Frame and in the
2 HO2S 2 sensor produces an output signal which Failure Records data.
indicates the oxygen storage capacity of the catalyst; this
in turn indicates the catalyst’s ability to convert exhaust Conditions for Clearing the MIL/DTC
gases efficiently. If the catalyst is operating efficiently, the D The PCM will turn the MIL “OFF” on the third
Bank 2 HO2S 1 signal will be far more active than that consecutive trip cycle during which the diagnostic has
produced by the Bank 2 HO2S 2 sensor. If the Bank 2 been run and the fault condition is no longer present.
HO2S 2 signal voltage remains excessively low for an D A history DTC P0157 will clear after 40 consecutive
extended period of time, DTC P0157 will be set. warm-up cycles have occurred without a fault.
D No related DTCs. feed.
D The engine is operating in “closed loop.”
Diagnostic Aids measurement that is not correct. Disconnect the MAF
sensor to see if the condition is corrected. If so, replace
Check for the following conditions: the MAF sensor.
D Heated oxygen sensor wiring – The sensor pigtail may D Fuel contamination – Water, even in small amounts,
be mispositioned and contacting the exhaust system. can be delivered to the fuel injectors. The water can
D Poor PCM to engine grounds. cause a lean exhaust to be indicated. Excessive
D Fuel pressure – A condition which causes a lean alcohol in the fuel can also cause this condition. Refer
exhaust can cause DTC P0157 to set. The system will to Fuel System Diagnosis for the procedure to check
go lean if pressure is too low. The PCM can for fuel contamination.
compensate for some decrease. However, if fuel D If none of above conditions are present, replace the
pressure is too low, a DTC P0157 may be set. Refer affected HO2S 2.
to Fuel System Diagnosis.
D Lean injector(s) – Perform “Injector Balance Test.” Test Description
D Vacuum leaks – Check for disconnected or damaged Number(s) below refer to the step number(s) on the
vacuum hoses and for vacuum leaks at the intake Diagnostic Chart.
3. DTC P0157 failing during operation may indicate a
D Exhaust leaks – An exhaust leak may cause outside air condition described in the “Diagnostic Aids” above.
to be pulled into the exhaust gas stream past the
HO2S, causing the DTC P0157 to set. Check for If the DTC P0157 test passes while the Failure
exhaust leaks near the Bank 1 HO2S 2 sensor. Records conditions are being duplicated, an
intermittent condition is indicated.
D MAF sensor – The system can go lean if the MAF
sensor signal indicates an engine airflow
DTC P0157 – HO2S Circuit Low Voltage Bank 2 Sensor 2

performed? System
2. Review and record Tech 2 Failure Records data and
note parameters.
ground circuit.
DTC P0157 – HO2S Circuit Low Voltage Bank 2 Sensor 2 (Cont'd)

signal circuits.
2. Reconnect the PCM, leave HO2S 2 disconnected.
9 Replace the PCM.
procedures.
And also refer to the latest Service Bulletin.

D06RY00177
Circuit Description D Engine coolant temperature is above 60°C (140°F).

To control emissions of hydrocarbons (HC), carbon D Bank 2 HO2S 2 signal voltage remains above 952 mV
monoxide (CO), and oxides of nitrogen (NOx), a during normal “closed loop” operation for a total of 106
seconds over a 125-second period.
three-way catalytic converter is used. The catalyst within
OR
the converter promotes a chemical reaction which
oxidizes the HC and CO present in the exhaust gas, D Bank 2 HO2S 2 signal voltage remains above 500 mV
during deceleration fuel cutoff mode operation for up to
converting them into harmless water vapor and carbon 3 seconds.
dioxide. The catalyst also reduces NOx, converting it to
nitrogen. The powertrain control module (PCM) has the Action Taken When the DTC Sets
ability to monitor this process using the Bank 2 HO2S 1
and the Bank 2 HO2S 2 heated oxygen sensors. The D The PCM will illuminate the malfunction indicator lamp
Bank 2 HO2S 1 sensor produces an output signal which
indicates the amount of oxygen present in the exhaust when the DTC was set as Freeze Frame and in the
gas entering the three-way catalytic converter. The Bank Failure Records data.
2 HO2S 2 sensor produces an output signal which
indicates the oxygen storage capacity of the catalyst; this Conditions for Clearing the MIL/DTC
in turn indicates the catalyst’s ability to convert exhaust
gases efficiently. If the catalyst is operating efficiently, the consecutive trip cycle during which the diagnostic has
Bank 2 HO2S 1 signal will be far more active than that been run and the fault condition is no longer present.
produced by the Bank 2 HO2S 2 sensor. If the Bank 2 D A history DTC P0158 will clear after 40 consecutive
HO2S 2 signal voltage remains excessively high for an warm-up cycles have occurred without a fault.
extended period of time, DTC P0158 will be set. D DTC P0158 can be cleared by using the Tech 2 “Clear
Conditions for Setting the DTC feed.
D No related DTCs.
D Engine is operating in “closed loop.”
D “Closed loop” commanded air/fuel ratio is between
14.5 and 14.8.
Diagnostic Aids indicated by a powdery deposit on the portion of the
HO2S exposed to the exhaust stream. If
Check for the following conditions: contamination is noticed, replace the affected HO2S.
D Fuel pressure – An excessively rich fuel mixture can D Open HO2S signal or low circuit, or faulty HO2S – A
cause a DTC P0158 to be set. Refer to Fuel System poor connection or open in the HO2S signal or low
Diagnosis. circuit can cause the DTC to set during deceleration
D Rich injector(s) – Perform “Injector Balance Test.” fuel cutoff mode operation. An HO2S which is faulty
D Leaking injector – Refer to Fuel System Diagnosis. and does not allow full voltage swing between the rich
D Evaporative emissions (EVAP) canister purge – Check and lean thresholds can also cause this condition.
for fuel saturation. If full of fuel, check canister control Operate the vehicle while monitoring the HO2S voltage
and hoses. Refer to Evaporative Emission (EVAP) with a Tech 2. If the HO2S voltage is limited within a
Control System. range between 300 mV to 600 mV, check the HO2S
signal and low circuit wiring and associated terminal
D MAF sensor –The system can go rich if the MAF connections. If the wiring and connections are OK,
sensor signal indicates an engine airflow replace the HO2S.
measurement that is not correct. Disconnect the MAF
sensor to see if a rich condition is corrected. If so, D If none of above conditions are present, replace the
replace the MAF sensor. affected HO2S.
D Check for a leaking fuel pressure regulator diaphragm Test Description
by checking the vacuum line to the regulator for the
presence of fuel. There should be no fuel in the Number(s) below refer to the step number(s) on the
vacuum line. Diagnostic Chart.
D TP sensor – An intermittent TP sensor output will 3. DTC P0158 being set during deceleration fuel cutoff
cause the system to go rich, due to a false indication mode operation may indicate a condition described
of the engine accelerating. in the “Diagnostic Aids” above. If the DTC P0158
D Shorted Heated Oxygen Sensor (HO2S) – If the HO2S test passes while the Failure Records conditions are
is internally shorted, the HO2S voltage displayed on being duplicated, an intermittent condition is
the Tech 2 will be over 1 volt. Try disconnecting the indicated.
affected HO2S with the key “ON,” engine “OFF.” If the
displayed HO2S voltage changes from over 1000 mV Reviewing the Failure Records vehicle mileage since the
to around 450 mV, replace the HO2S. Silicon diagnostic test last failed may help determine how often
contamination of the HO2S can also cause a high the condition that caused the DTC to be set occurs. This
HO2S voltage to be indicated. This condition is may assist in diagnosing the condition.

performed? System
(500 mV in
Does the Bank 2 HO2S 2 voltage remain above the fuel cut-out

4. At the HO2S Bank 2 Sensor 2 connector (PCM
side), use a DVM to measure voltages at the high
and low signal terminals.
side) to ground.
Is Bank 2 HO2S 2 voltage between the specified Diagnostic
8 Replace the PCM.
procedures.

D06RY00177
Circuit Description 2 HO2S 1 to become active. Oxygen sensor heaters are

To control emissions of hydrocarbons (HC), carbon required by post-catalyst monitor sensors to maintain a
monoxide (CO), and oxides of nitrogen (NOx), a sufficiently high temperature for accurate exhaust oxygen
three-way catalytic converter is used. The catalyst within content readings further from the engine.
the converter promotes a chemical reaction which
oxidizes the HC and CO present in the exhaust gas,
converting them into harmless water vapor and carbon D No related DTCs.
dioxide. The catalyst also reduces NOx, converting it to D Battery voltage is above 10 volts.
nitrogen. The powertrain control module (PCM) has the D Engine run time is longer than 40 seconds.
ability to monitor this process using the Bank 2 HO2S 1 D Oxygen sensor heater is functioning properly.
and the Bank 2 HO2S 2 heated oxygen sensors. The D Engine is in “closed loop” operation.
Bank 2 HO2S 1 sensor produces an output signal which
D Bank 2 HO2S 2 signal voltage remains between
indicates the amount of oxygen present in the exhaust 426 mV and 474 mV for a total of 106 seconds over a
gas entering the three-way catalytic converter. The Bank 125-second period of time.
2 HO2S 2 sensor produces an output signal which
indicates the oxygen storage capacity of the catalyst; this Action Taken When the DTC Sets
in turn indicates the catalyst’s ability to convert exhaust D The PCM will illuminate the malfunction indicator lamp
gases efficiently. If the catalyst is operating efficiently, the (MIL) the first time the fault is detected.
Bank 2 HO2S 1 signal will be far more active than that D The PCM will store conditions which were present
produced by the Bank 2 HO2S 2 sensor. If the Bank 2 when the DTC was set as Freeze Frame and in the
HO2S 2 signal voltage remains between 400 mV and Failure Records data.
500 mV for an extended period of time, DTC P0160 will be
set. Conditions for Clearing the MIL/DTC
Heated Oxygen sensors are used to minimize the amount D The PCM will turn the MIL “OFF” on the third
of time required for “closed loop” fuel control operation consecutive trip cycle during which the diagnostic has
and allow accurate catalyst monitoring. The oxygen been run and the fault condition is no longer present.
sensor heater greatly decreases the amount of time D A history DTC P0160 will clear after 40 consecutive
required for fuel control sensors Bank 1 HO2S 1 and Bank warm-up cycles have occurred without a fault.
D DTC P0160 can be cleared by using the Tech 2 “Clear D Intermittent test – With the ignition “ON,” monitor the
Info” function or by disconnecting the PCM battery HO2S signal voltage while moving the wiring harness
feed. and related connectors. If the fault is induced, the
HO2S signal voltage will change. This may help isolate
Diagnostic Aids the location of the malfunction.
Test Description
harness connectors for backed-out terminals, Number(s) below refer to the step number(s) on the
improper mating, broken locks, improperly formed or Diagnostic Chart.
damaged terminals, poor terminal-to-wire connection, 3. If the DTC P0160 test passes while the Failure
and damaged harness. Records conditions are being duplicated, an
D Faulty HO2S heater or heater circuit – With the ignition intermittent condition is indicated.
“ON,” engine “OFF,” the HO2S voltage displayed on a Reviewing the Failure Records vehicle mileage since the
Tech 2 should gradually drop to below 250 mV. If not,
disconnect the HO2S and connect a test light between diagnostic test last failed may help determine how often
the HO2S ignition feed and heater ground circuits. If the condition that caused the DTC to be set occurs. This
the test light does not light, repair the open ignition feed may assist in diagnosing the condition.
or sensor ground circuit as necessary. If the test light
lights and the HO2S signal and low circuits are OK,
replace the HO2S.
DTC P0160 – HO2S Circuit Insufficient Activity Bank 2 Sensor 2

performed? System
minutes.
Was problem found? — Verify repair Go to Step 5
Did either terminal require replacement? — Verify repair Go to Step 6
terminal connections at the PCM and replace terminals
if necessary.
DTC P0160 – HO2S Circuit Insufficient Activity Bank 2 Sensor 2 (Cont'd)

ohms, repair open or poor connections as
necessary.
3. If the Bank 2 HO2S 2 low circuit measures over 5
ohms, repair open or poor connections as
necessary.
11 Replace the PCM.
procedures.
D06RY00177

of time required for “closed loop” fuel control operation D IAT and ECT are within 6°C (11°F) of each other at
start-up.
sensor heater greatly decreases the amount of time D Ignition voltage is between 11 volts and 18 volts.
required for fuel control sensors Bank 1 HO2S 1 and Bank D Average mass air flow for the sample period is less
2 HO2S 1 to become active. Oxygen sensor heaters are than 23 g/second.
required by post-catalyst monitor sensors to maintain a D Bank 2 HO2S 2 voltage does not change more than
sufficiently high temperature which allows accurate 150 mV from the bias voltage (between
400 mV-500 mV) for a longer amount of time than it
exhaust oxygen content readings further from the engine. should. The maximum amount of time to come up to
once during an ignition cycle. When the engine is started,
the PCM will monitor the HO2S voltage. When the Bank 2 Action Taken When the DTC Sets
HO2S 2 voltage indicates a sufficiently active sensor, the D The PCM will illuminate the malfunction indicator lamp
engine (more total air flow = shorter time to HO2S Conditions for Clearing the MIL/DTC
activity). D The PCM will turn the MIL “OFF” on the third
at start-up.
Diagnostic Chart.
Diagnostic Aids 2. The HO2S should be allowed to cool before
Check for the following conditions: performing this test. If the HO2S heater is
functioning, the signal voltage will gradually increase
for backed-out terminals, improper mating, broken or decrease as the sensor element warms. If the
locks, improperly formed or damaged terminals, and heater is not functioning, the HO2S signal will
poor terminal-to-wire connection. remain near the 450 mV bias voltage.
D Damaged harness – Inspect the wiring harness for 4. This ensures that the ignition feed circuit to the
damage. If the harness appears to be OK, observe the HO2S is not open or shorted. The test light should
display on the Tech 2 while moving connectors and be connected to a good chassis ground, in case the
wiring harnesses related to the sensor. A change in the HO2S low or HO2S heater ground circuit is faulty.
Reviewing the Failure Records vehicle mileage since the 5. This checks the HO2S heater ground circuit.
diagnostic test last failed may help determine how often 6. This checks for an open or shorted HO2S heater
the condition that caused the DTC to be set occurs. This element.
may assist in diagnosing the condition. 11.An open HO2S signal or low circuit can cause the
HO2S heater to appear faulty. Check these circuits

performed? System
proceeding.
fuses.
Did the HO2S voltage go from bias voltage to above or Below Diagnostic
4. Using a test light connected to a known good ground
(do not use Bank 2 HO2S 2 heater ground or Bank 2
side).

2. Using a DVM, measure resistance between the
Bank 2 HO2S 2.
harness terminals.
2. If a poor connection is found, replace the terminals.
2 low circuit.
2 low circuit.
necessary.
necessary.
15 Locate and repair the short to ground in the Bank 2
HO2S 2 ignition feed circuit and replace the faulty fuse.
Diagnostic Trouble Code (DTC) P0171 Fuel Trim System Lean Bank 1
D06RY00171
Circuit Description D Engine coolant temperature is between 25°C (77°F)

and 100°C (212°F).
To provide the best possible combination of driveability,
fuel economy, and emission control, a “closed loop” D Intake air temperature is between –40°C (–40°F) and
120°C (248°F).
air/fuel metering system is used. While in “closed loop,”
the powertrain control module (PCM) monitors the Bank 1 D Manifold absolute pressure is between 24 kPa and 99
kPa.
HO2S 1 and Bank 2 HO2S 1 signals and adjusts fuel
delivery based upon the HO2S signal voltages. A change D Throttle angle is steady below 95%.
made to fuel delivery will be indicated by the long and D Vehicle speed is below 136 km/h (85 mph).
short term fuel trim values which can be monitored with a D Engine speed is between 400 and 6,000 RPM.
Tech 2. Ideal fuel trim values are around 0%; if the HO2S D Barometric pressure is greater than 72.5 kPa.
signals are indicating a lean condition the PCM will add D Mass air flow is between 2 g/second and 200 g/second.
fuel, resulting in fuel trim values above 0%. If a rich D Ignition voltage is above 9.5 volts.
condition is detected, the fuel trim values will be below D Fuel system is in “closed loop.”
0%, indicating that the PCM is reducing the amount of fuel D Canister purge duty cycle is greater than 0% if on.
delivered. If an excessively lean condition is detected on
Bank 1, the PCM will set DTC P0171. Action Taken When the DTC Sets
The PCM’s maximum authority to control long term fuel
trim allows a range between –15% (automatic D The PCM will illuminate the malfunction indicator lamp
(MIL) after the second consecutive trip in which the
transmission) or –12% (manual transmission) and +20%. fault is detected.
The PCM monitors fuel trim under various engine
speed/load fuel trim cells before determining the status of when the DTC was set as Freeze Frame and in the
the fuel trim diagnostic. Failure Records data.
Conditions for Setting the DTC Conditions for Clearing the MIL/DTC
D No Tech 2 test is being run. D The PCM will turn the MIL “OFF” on the third
D None of the following: EGR DTCs, HO2S DTCs, consecutive trip cycle during which the diagnostic has
(response, transition, open, low volts, no activity), MAF been run and the fault condition is no longer present.
DTCs, TP sensor DTCs, MAP DTCs, IAT DTCs,
canister purge DTCs, EVAP DTCs, injector circuit D A history DTC P0171 will clear after 40 consecutive
DTCs, or misfire DTCs. warm-up cycles have occurred without a fault.
feed.
Diagnostic Aids
connectors and wiring harnesses related to the engine
harness. A change in the display will indicate the
location of the fault.
Test Description
Diagnostic Chart.
2. DTCs other than P0171 and P0174 may indicate a
condition present which may cause a lean condition.
If this is the case, repairing the condition which
caused the other DTC will most likely correct the
DTC P0171/P0174.
4. If the DTC P0171 test passes while the Failure
Records conditions are being duplicated, the lean
condition is intermittent. Refer to Diagnostic Aids or
Symptoms for additional information on diagnosing
intermittent problems.
DTC P0171 – Fuel Trim System Lean Bank 1

performed? System
2 Are any DTCs set other than P0171 and P0174? Go to the
applicable
DTC charts
and repair the
other DTCs
before
proceeding
— with this chart Go to Step 3
3 1. Start the engine and operate the vehicle in “closed
loop.”
2. Observe the “BANK 1 L.T. FUEL TRIM” display on
the Tech 2. L.T. Fuel
Is the displayed value greater than the specified value? Trim: +20% Go to Step 5 Go to Step 4
4 1. Review and record the Tech 2 Failure Records data.
2. Clear the DTC P0171/P0174 and operate the
vehicle to duplicate the Failure Records conditions. The lean
3. Monitor the Tech 2 “DTC” info for DTC P0171 while condition is
operating the vehicle to duplicate the Failure not present.
Records conditions. If a
driveability
4. Continue operating the vehicle until the DTC P0171 symptom still
test runs and note the test result. exists, refer
Does the Tech 2 indicate DTC P0171 failed this to Symptoms
ignition? — Go to Step 5 section.
5 Was DTC P0174 also set? — Go to Step 6 Go to Step 15
6 Visually and physically inspect the vacuum hoses for
disconnections, splits, kinks, improper routing and
improper connections and repair any problem found.
Did your inspection reveal a problem requiring repair? — Verify repair Go to Step 7
7 Visually and physically inspect the crankcase
ventilation valve for proper installation and repair any
problem found (refer to Crankcase Ventilation
System).
8 1. Inspect the MAF sensor inlet screen for damage or
for the presence of foreign objects which may
partially block the air flow sample through the MAF
sensor.
2. Correct any problem that is found as necessary.
Did your inspection of the MAF sensor reveal a
condition requiring repair? — Verify repair Go to Step 9
9 Start the engine and note the idle quality.
Is a high or unsteady idle being experienced? — Go to Step 10 Go to Step11
10 1. Visually and physically inspect the throttle body,
intake manifold, EGR valve and the EGR feed pipe
for vacuum leaks.
2. Repair any vacuum leaks as necessary.
Did your inspection reveal a vacuum leak? — Verify repair Go to Step 11
DTC P0171 – Fuel Trim System Lean Bank 1 (Cont'd)

11 Check the fuel for excessive water, alcohol, or other
contaminants (see Diagnosis in Engine Fuel for the
procedure) and correct the contaminated fuel condition
if present (see Engine Fuel).
Was the fuel contaminated? — Verify repair Go to Step 12
12 1. Visually and physically inspect the PCM injector
grounds, power grounds and sensor grounds to
ensure that they are clean, tight, and in their proper
locations.
2. If a faulty ground condition is present, correct it as
necessary.
Did your inspection reveal a condition requiring repair? — Verify repair Go to Step 13
13 1. Disconnect the MAF sensor electrical connector.
2. Operate the vehicle in “closed loop” while
monitoring the “BANK 1 S.T. FUEL TRIM” displayed
on the Tech 2.
Does “BANK 1 S.T. FUEL TRIM” value decrease to
near the specified value? 0% Go to Step 19 Go to Step 14
14 Perform the procedure in the “Fuel System Pressure
Test” and repair fuel system problem if necessary.
Did Fuel System Pressure Test isolate a condition
requiring repair? — Verify repair Go to Step 15
15 1. Visually and physically inspect the intake manifold,
injector O-rings, EGR adapter, EGR valve and the
EGR feed pipes for vacuum leaks.
2. Repair any problem that is found.
Did your inspection reveal a problem? — Verify repair Go to Step 16
16 Visually and physically inspect the Bank 1 exhaust
manifold for leaks and loose or missing hardware and
correct any problem found.
17 Perform the “Injector Balance Test,” and correct any
problem found (refer to Fuel Metering System).
Did Injector Balance Test isolate a problem? — Verify repair Go to Step 18
18 1. Visually and physically inspect the Bank 1 HO2S 1
to ensure that it is installed securely and that the
Bank 1 HO2S 1 pigtail and wiring harness are not
contacting the exhaust or otherwise damaged.
Refer to
2. If a problem is found, correct it as necessary. Diagnostic
Did your inspection reveal a problem? — Verify repair Aids
Diagnostic Trouble Code (DTC) P0172 Fuel Trim System Rich Bank 1
D06RY00171
Circuit Description D None of the following was set: EGR DTCs, HO2S
DTCs, (response, transition, open, low volts, no
To provide the best possible combination of driveability, activity), MAF DTCs, TPS DTCs, MAP DTCs, IAT
fuel economy, and emission control, a “closed loop” DTCs, canister purge DTCs, EVAP DTCs, injector
air/fuel metering system is used. While in “closed loop,” circuit DTCs, or misfire DTCs.
the powertrain control module (PCM) monitors the Bank 1 D Engine coolant temperature is between 25°C (77°F)
heated oxygen sensors (HO2S) 1 and Bank 2 HO2S 1 and 100°C (212°F).
signals and adjusts fuel delivery based upon the HO2S D Intake air temperature is between –40°C (–40°F) and
signal voltages. A change made to fuel delivery will be 120°C (248°F).
indicated by the long and short term fuel trim values which D Manifold absolute pressure is between 24 kPa and 99
can be monitored with a Tech 2. Ideal fuel trim values are kPa.
around 0%; if the HO2S signals are indicating a lean D Throttle angle is steady below 95%.
condition the PCM will add fuel, resulting in fuel trim D Vehicle speed is below 136 km/h (85 mph).
values above 0%. If a rich condition is detected, the fuel D Engine speed is between 400 and 6,000 RPM.
trim values will be below 0%, indicating that the PCM is
D Barometric pressure is greater than 72.5 kPa.
reducing the amount of fuel delivered. If an excessively
rich condition is detected on Bank 1, the PCM will set DTC D Mass air flow is between 2 g/second and 200 g/second.
P0172. D Ignition voltage is above 9.5 volts.
The PCM’s maximum authority to control long term fuel D Fuel system is in “closed loop.”
trim allows a range between –15% (automatic D Canister purge duty cycle is greater than 0%, if “ON.”
transmission) or –12 (manual transmission) and +20%.
The PCM’s maximum authority to control short term fuel Action Taken When the DTC Sets
trim allows a range between –11% and +20%. The PCM D The PCM will illuminate the malfunction indicator lamp
monitors fuel trim under various engine speed/load fuel (MIL) after the second consecutive trip in which the
trim cells before determining the status of the fuel trim fault is detected.
diagnostic. D The PCM will store conditions which were present
Conditions for Setting the DTC Failure Records data.
D No Tech 2 test is being run.
Conditions for Clearing the MIL/DTC harness. A change in the display will indicate the
D The PCM will turn the MIL “OFF” on the third Reviewing the Failure Records vehicle mileage since the
been run and the fault condition is no longer present. diagnostic test last failed may help determine how often
warm-up cycles have occurred without a fault. may assist in diagnosing the condition.
Diagnostic Chart.
Diagnostic Aids 2. DTCs other than P0172 and P0175 may indicate a
Check for the following conditions: condition present which may cause a lean condition.
D Poor connection at PCM – Inspect harness connectors If this is the case, repairing the condition which
for backed-out terminals, improper mating, broken caused the other DTC will most likely correct the
locks, improperly formed or damaged terminals, and DTC P0172/P0175.
poor terminal-to-wire connection. 4. If the DTC P0172 test passes while the Failure
D Damaged harness – Inspect the wiring harness for Records conditions are being duplicated, the rich
damage. If the harness appears to be OK, observe the condition is intermittent. Refer to Diagnostic Aids or
Bank 1 HO2S 1 display on the Tech 2 while moving Symptoms for additional information on diagnosing
DTC P0172 – Fuel Trim System Rich Bank 1

performed? System
applicable
DTC charts
and repair the
other DTCs
before
proceeding
— with this chart Go to Step 3
loop.” L.T. Fuel
2. Observe “B1 Long Term Fuel Trim” display on the Trim: –15%
Tech 2. (auto. trans.)
Is the displayed value more negative than the specified OR –12%
value? (man. trans.) Go to Step 5 Go to Step 4
vehicle to duplicate the Failure Records conditions.
3. Monitor the Tech 2 “DTC” info for DTC P0172 while The rich
operating the vehicle to duplicate the Failure condition is
Records conditions. not present.
If a
4. Continue operating the vehicle until the DTC P0172 driveability
test runs and note test result. symptom still
Does the Tech 2 indicate DTC P0172 failed this exists, refer
ignition? — Go to Step 5 to Symptoms.
5 Is DTC P0175 also set? — Go to Step 6 Go to Step 15
6 Visually and physically inspect the air filter element and
replace it if necessary.
Did the air filter require replacement? — Verify repair Go to Step 7
DTC P0172 – Fuel Trim System Rich Bank 1 (Cont'd)

7 Visually and physically inspect the air intake duct for
collapse or restriction and repair if necessary.
8 Inspect the MAF sensor inlet screen for damage or for
the presence of foreign objects which may partially
block air flow through the screen and correct any
problem found.
condition requiring repair or replacement? — Verify repair Go to Step 9
Is a low or unsteady idle being experienced? — Go to Step 10 Go to Step 11
2. Physically inspect the throttle body bore and throttle
plate for coking and foreign objects.
3. If a problem was found, repair as necessary.
regulator and inspect the hose for the presence of
fuel.
2. If fuel is present in the vacuum hose, replace the
fuel pressure regulator (refer to Fuel Metering
System).
Did the fuel pressure regulator require replacement? — Verify repair Go to Step 12
12 Ignition “ON,” engine “OFF,” monitor the TP1 Angle
display on the Tech 2 while slowly depressing the
accelerator pedal.
Does the TP1 Angle display increase steadily and Minimum 8%
evenly from minimum value at closed throttle to Maximum
maximum value at wide-open throttle? 92% Go to Step 13 Go to Step 21
monitoring the “BANK 1 L.T. FUEL TRIM” and
“BANK 1 S. T. FUEL TRIM” display on the Tech 2.
Did both values change to near the specified value? 0% Go to Step 22 Go to Step 14
14 1. Perform “Fuel System Pressure Test.”
2. If Fuel System Pressure Test isolates a problem,
repair as necessary (refer to Engine Fuel or Fuel
Metering System).
Did the Fuel System Pressure Test isolate a problem
2. Connect a test light between the harness connector
terminals of canister purge solenoid.
Is the test light on? — Go to Step 16 Go to Step 19
16 Check for short to ground in the wire (red/yel) between
the canister purge solenoid and PCM terminal S7.
Was there a short to ground? — Go to Step 17 Go to Step 18

18 Replace the PCM.
procedures.
19 1. Perform the “Injector Balance Test.”
2. If Injector Balance Test isolates a problem, repair as
necessary (refer to Fuel Metering System).
Did the Injector Balance Test isolate a problem
20 1. Remove and visually/physically inspect the Bank 1
HO2S 1 for silicon contamination. This will be
indicated by a powdery deposit on the portion of the
HO2S that is exposed to the exhaust stream.
2. If contamination is evident on the Bank 1 HO2S 1, Refer to
replace the contaminated sensors. Diagnostic
Did the sensor require replacement? — Verify repair Aids
21 1. Check the TP sensor mounting screws and tighten
or replace them as necessary if they are loose or
missing.
2. If the screws are OK, replace the TP sensor.
Diagnostic Trouble Code (DTC) P0174 Fuel Trim System Lean Bank 2
D06RY00175
Circuit Description D Engine coolant temperature is between 25°C (77°F)

and 100°C (212°F).
fuel economy, and emission control, a “closed loop” D Intake air temperature is between –40°C (–40°F) and
120°C (248°F).
the powertrain control module (PCM) monitors the Bank 1 D Manifold absolute pressure is between 24 kPa and 99
kPa.
delivery based upon the HO2S signal voltages. A change D Throttle angle is steady between 3 and 95%.
made to fuel delivery will be indicated by the long and D Vehicle speed is below 136 km/h (85 mph).
short term fuel trim values which can be monitored with a D Engine speed is between 400 and 6,000 RPM.
Tech 2. Ideal fuel trim values are around 0%; if the HO2S D Barometric pressure is greater than 72.5 kPa.
signals are indicating a lean condition the PCM will add D Mass air flow is between 2 g/second and 200 g/second.
fuel, resulting in fuel trim values above 0%. If a rich D Ignition voltage is above 9.5 volts.
condition is detected, the fuel trim values will be below D Fuel system is in “closed loop.”
0%, indicating that the PCM is reducing the amount of fuel D Canister purge duty cycle is greater than 0%, if “ON.”
delivered. If an excessively lean condition is detected on
Bank 2, the PCM will set DTC P0174. Action Taken When the DTC Sets
The PCM’s maximum authority to control long term fuel
trim allows a range between –15%(automatic D The PCM will illuminate the malfunction indicator lamp
transmission) or –12%(manual transmission) and +20%. failure is detected.
The PCM monitors fuel trim under various engine
speed/load fuel trim cells before determining the status of when the DTC was set as Freeze Frame and in the
the fuel trim diagnostic. Failure Records data.
Conditions for Setting the DTC Conditions for Clearing the MIL/DTC
D No Tech 2 test is being run. D The PCM will turn the MIL “OFF” on the third
D None of the following DTCs are set: idle system, EGR, consecutive trip cycle during which the diagnostic has
HO2S, (response, transition, open, low volts, no been run and the fault condition is no longer present.
activity), MAF, TP sensor, MAP, IAT, canister purge, D A history DTC P0174 will clear after 40 consecutive
EVAP, injector circuit, or misfire. warm-up cycles have occurred without a fault.
feed.
Diagnostic Aids
harness. A change in the display will indicate the
Test Description
Diagnostic Chart.
2. DTCs other than P0171 and P0174 may indicate a
condition present which may cause a lean condition.
If this is the case, repairing the condition which
DTC P0171/P0174.
4. If the DTC P0174 test passes while the Failure
Records conditions are being duplicated, the lean
condition is intermittent. Refer to Diagnostic Aids or
Symptoms for additional information on diagnosing
DTC P0174 – Fuel Trim System Lean Bank 2

performed? System
applicable
DTC charts
and repair the
other DTCs
before
proceeding
with this
— chart. Go to Step 3
loop.”
2. Observe the “BANK 2 L.T. FUEL TRIM” display on
the Tech 2.
Is the displayed values greater than the specified L.T. Fuel
values? Trim: +20% Go to Step 5 Go to Step 4
4 1. Review and record Tech 2 Failure Records data.
3. Monitor the Tech 2 “DTC” info for DTC P0174 while The lean
operating the vehicle to duplicate the Failure condition is
Records conditions. not present.
4. Continue operating the vehicle until the DTC P0174 If a
test runs. driveability
symptom still
5. Note the test result. exists, refer
Does the Tech 2 indicate DTC P0174 failed this to Symptoms
ignition? — Go to Step 5 section.
6 Visually and physically inspect the vacuum hoses for
disconnections, splits, kinks, improper routing and
improper connections and repair any problem found.
7 Visually and physically inspect the crankcase
ventilation valve for proper installation and repair any
problem found (refer to Crankcase Ventilation
System).
for the presence of foreign objects which may
partially block the air flow sample through the MAF
sensor.
2. Correct any problem that is found as necessary.
condition requiring repair? — Verify repair Go to Step 9
Is a high or unsteady idle being experienced? — Go to Step 10 Go to Step 11
DTC P0174 – Fuel Trim System Lean Bank 2 (Cont'd)

10 1. Visually and physically inspect the throttle body,
intake manifold, EGR valve and the EGR feed pipe
for vacuum leaks.
2. Repair any vacuum leaks as necessary.
11 Check the fuel for excessive water, alcohol, or other
contaminants (see Diagnosis in Engine Fuel for
procedure) and correct the contaminated fuel condition
is present (see Engine Fuel).
ensure that they are clean, tight, and in their proper
locations.
2. If a faulty ground condition is present, correct it as
necessary.
monitoring the “BANK 2 S.T. FUEL TRIM” displayed
on the Tech 2.
Does the “BANK 2 S.T. FUEL TRIM” value decrease to
near the specified value? 0% Go to Step 19 Go to Step 14
14 Perform the procedure in the ”Fuel System Pressure
Test” and repair fuel system problem if necessary.
Did the Fuel System Pressure Test isolate a condition
15 1. Visually and physically inspect the intake manifold,
injector O-rings, EGR adapter, EGR valve and the
EGR feed pipes for vacuum leaks.
2. Repair any problem that is found.
16 Visually and physically inspect the Bank 2 exhaust
manifold for leaks and loose or missing hardware and
correct any problem found.
17 Perform the “Injector Balance Test,” and correct any
problem found (refer to Fuel Metering System).
Did the Injector Balance Test isolate a problem? — Verify repair Go to Step 18
18 1. Visually and physically inspect the Bank 2 HO2S 1
to ensure that it is installed securely and that the
Bank 2 HO2S 1 pigtail and wiring harness are not
contacting the exhaust or otherwise damaged.
Refer to
2. If a problem is found, correct it as necessary. Diagnostic
Did your inspection reveal a problem? — Verify repair Aids
Diagnostic Trouble Code (DTC) P0175 Fuel Trim System Rich Bank 2
D06RY00175
Circuit Description activity), MAF, TPS, MAP, IAT, canister purge, EVAP,
injector circuit, or misfire.
fuel economy, and emission control, a “closed loop” D Engine coolant temperature is between 25°C (77°F)
and 100°C (212°F).
the powertrain control module (PCM) monitors the Bank 1 D Intake air temperature is between –40°C (–40°F) and
120°C (248°F).
delivery based upon the HO2S signal voltages. A change D Manifold absolute pressure is between 24 kPa and 99
kPa.
made to fuel delivery will be indicated by the long and
short term fuel trim values which can be monitored with a D Throttle angle is steady between 3 and 95%.
Tech 2. Ideal fuel trim values are around 0%; if the HO2S D Vehicle speed is below 136 km/h (85 mph).
signals are indicating a lean condition the PCM will add D Engine speed is between 400 and 6,000 RPM.
fuel, resulting in fuel trim values above 0%. If a rich D Barometric pressure is greater than 72.5 kPa.
condition is detected, the fuel trim values will be below D Mass air flow is between 2 g/second and 200 g/second.
0%, indicating that the PCM is reducing the amount of fuel D Ignition voltage is above 9.5 volts.
delivered. If an excessively rich condition is detected on D Fuel system is in “closed loop.”
Bank 2, the PCM will set DTC P0175.
The PCM’s maximum authority to control long term fuel Action Taken When the DTC Sets
trim allows a range between –15%(automatic
transmission) or –12%(manual transmission) and +20%. (MIL) after the second consecutive trip in which the
The PCM’s maximum authority to control short term fuel failure is detected.
trim allows a range between –11% and +20%. The PCM D The PCM will store conditions which were present
monitors fuel trim under various engine speed/load fuel when the DTC was set as Freeze Frame and in the
trim cells before determining the status of the fuel trim Failure Records data.
diagnostic.
D No Tech 2 test is being run. consecutive trip cycle during which the diagnostic has
D None of the following DTCs are set: idle system, EGR, been run and the fault condition is no longer present.
HO2S, (response, transition, open, low volts, no D A history DTC P0175 will clear after 40 consecutive
D DTC P0175 can be cleared by using the Tech 2 “Clear the condition that caused the DTC to be set occurs. This
Info” function or by disconnecting the PCM battery may assist in diagnosing the condition.
feed.
Test Description
Diagnostic Aids Number(s) below refer to the step number(s) on the
Check for the following conditions: Diagnostic Chart.
D Poor connection at PCM – Inspect harness connectors 2. DTCs other than P0172 and P0175 may indicate a
for backed -out terminals, improper mating, broken condition present which may cause a lean condition.
poor terminal-to-wire connection. If this is the case, repairing the condition which
D Damaged harness – Inspect the wiring harness for DTC P0172/P0175.
Bank 2 HO2S 1 display on the Tech 2 while moving 4. If the DTC P0175 test passes while the Failure
connectors and wiring harnesses related to the engine Records conditions are being duplicated, the rich
harness. A change in the display will indicate the condition is intermittent. Refer to Diagnostic Aids or
location of the fault. Symptoms for additional information on diagnosing
Reviewing the Failure Records Vehicle mileage since the intermittent problems.
DTC P0175 – Fuel Trim System Rich Bank 2

1 Was the ”On-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
applicable
DTC charts
and repair the
other DTCs
before
proceeding
with this
— chart. Go to Step 3
loop.” L.T. Fuel
2. Observe the “BANK 2 L.T. FUEL TRIM” display on Trim: –15%
the Tech 2. (auto. trans.)
Is the displayed value more negative than the specified OR –12%
value? (man. trans.) Go to Step 5 Go to Step 4
3. Monitor the Tech 2 “DTC” info for DTC P0175 while
operating the vehicle to duplicate the Failure The rich
Records conditions. condition is
4. Continue operating the vehicle until the DTC P0175 not present.
test runs. If a
driveability
5. Note the test result. symptom still
Does the Tech 2 indicate DTC P0175 failed this exists, refer
ignition? — Go to Step 5 to Symptoms.
6 Visually and physically inspect the air filter element and
replace it if necessary.
Did the air filter require replacement? — Verify repair Go to Step 7
7 Visually and physically inspect the air intake duct for
collapse or restriction and repair if necessary.

8 Inspect the MAF sensor inlet screen for damage or for
the presence of foreign objects which may partially
block air flow through the screen and correct any
problem found.
Is a low or unsteady idle being experienced? — Go to Step 10 Go to Step 11
10 1. Turn the ignition off and physically inspect the
throttle body bore, throttle plate, and IAC passages
for coking and foreign objects.
2. If a problem was found, repair as necessary.
regulator and inspect the hose for the presence of
fuel.
2. If fuel is present in the vacuum hose, replace the
fuel pressure regulator (refer to Fuel Metering
System).
Did the fuel pressure regulator require replacement? — Verify repair Go to Step 12
2. Monitor the TP Angle display on the Tech 2 while
slowly depressing the accelerator pedal.
Does the TP Angle display increase steadily and Minimum 8%
evenly from minimum value at closed throttle to Maximum
maximum value at wide-open throttle? 92% Go to Step 13 Go to Step 21
monitoring the “BANK 2 L.T. FUEL TRIM” and
“BANK 2 S.T. FUEL TRIM” display on the Tech 2.
Did both values change to near the specified value? 0% Go to Step 22 Go to Step 14
14 1. Perform the “Fuel System Pressure Test.”
2. If Fuel System Pressure Test isolates a problem,
repair as necessary (refer to Engine Fuel or Fuel
Metering System).
Did the Fuel System Pressure Test isolate a condition
2. Connect a test light between the harness connector
terminals of canister purge solenoid.
Is the test light on? — Go to Step 16 Go to Step 19
16 Check for short to ground in the wire (red/yel) between
the canister purge solenoid and PCM terminal S-7.
Was there a short to ground? — Go to Step 17 Go to Step 18

18 Replace the PCM.
procedures.
19 1. Perform the “Injector Balance Test.”
2. If the Injector Balance Test isolates a problem,
repair as necessary (refer to Fuel Metering
System).
Did the Injector Balance Test isolate a problem
20 1. Remove and visually/physically inspect the Bank 2
HO2S 1 for silicon contamination. This will be
indicated by a powdery deposit on the portion of the
HO2S that is exposed to the exhaust stream.
2. If contamination is evident on the Bank 2 HO2S 1, Refer to
replace the contaminated sensor. Diagnostic
Did the sensor require replacement? — Verify repair Aids
21 1. Check the TP sensor mounting screws and tighten
or replace them as necessary if they are loose or
missing.
2. If the screws are OK, replace the TP sensor.
Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit
D06RY00086

The powertrain control module (PCM) has six individual D The PCM will turn “OFF” the MIL on the third
injector driver circuits. Each controls an injector. When a consecutive trip cycle in which the diagnostic has been
driver circuit is grounded by the PCM, the injector is run and the fault is no longer present.
activated. The PCM monitors the current in each driver D A history DTC P0201 will clear after 40 consecutive
circuit. The voltage on each driver is monitored to detect warm-up cycles occur without a fault.
a fault. If the voltage is not what the PCM expects to D DTC P0201 can be cleared by using the Tech 2 “Clear
monitor on the circuit, a DTC is set. This DTC is also set if Info” function or by disconnecting the PCM battery
an injector driver is shorted to voltage or if there is an open feed.
circuit.
Diagnostic Aids
Conditions for Setting the DTC An injector driver circuit that is open or shorted to voltage
D The battery voltage is more than 9 volts. will cause a DTC P0201 to set. It will also cause a misfire
due to an inoperative injector. A misfire DTC will also be
D The engine is turning, determined by 58X crankshaft
position input signal. set indicating which cylinder is inoperative.
Long term and short term fuel trims that are excessively
D The injector voltage does not equal the ignition voltage
when the injector is commanded “OFF” or the injector high or low are a good indication that an injector is faulty.
voltage does not equal 0 volts when the injector is Use Fuel Injector Coil Test Procedure to check for faulty
commanded “ON.” injectors.
D The above conditions are met for 15 seconds.
Test Description
Action Taken When the DTC Sets The number(s) below refer to the step number(s) on the
D The PCM will illuminate the malfunction indicator lamp Diagnostic Chart.
(MIL) the first time the fault is detected. 3. This step determines if DTC P0201 is the result of a
D The PCM will store conditions which were present hard failure or an intermittent condition.
5. A special injector test connector is provided so that 7. Because the test light was “ON” steady, voltage to
the injectors can be electrically tested without the injector is OK, but the driver circuit is grounded
removal of the manifold. The test connector can be at all times. This step determines if the circuit is
identified by the blue connector lock which is shorted to ground or the PCM is faulty.
tethered to the wiring harness. If the light for 9. The reading should be about 12-14W.
cylinder 1 is “ON” steady before cranking the engine
as well as while cranking the engine, then the 10.Locating the open in the harness or in the injector
injector driver circuit is shorted to ground. will require removal of the manifold to provide
access.
If the test light blinks while cranking, the PCM and
the wiring to the injectors are OK. The Fuel
Injector Coil Test Procedure will check if the
injectors are faulty.
R321054
DTC P0201 – Injector 1 Control Circuit

performed? System
2 Will the engine start? Go to Engine
Cranks But
Will Not Run
— Go to Step 3 chart
3 1. Install the Tech 2. Clear the DTC.
2. Idle the engine for one minute.
Does DTC P0201 reset? — Go to Step 5 Go to Step 4
4 1. Review the Freeze Frame data with the ignition
“ON” and the engine “OFF” and note the
parameters.
2. Operate the vehicle within the Freeze Frame Go to
conditions as noted. Diagnostic
Does P0201 reset? — Go to Step 5 Aids
DTC P0201 – Injector 1 Control Circuit (Cont'd)

2. Disconnect the injector connector.
3. Install an injector test light J-39021-65 on the
injector test connector. Go to Fuel
Injector Coil
4. Crank the engine and note the light. Test
Does the injector test light blink? — Procedure Go to Step 6
6 Note whether the injector test light for cylinder 1 was
“OFF” or “ON” steady in step 5.
Was the test light “ON” steady while cranking the
engine? — Go to Step 7 Go to Step 9
7 1. Disconnect the PCM connector for the affected
injectors.
2. With a test light connected to B+, probe the affected
8 Repair short to ground in the injector driver circuit. Go to OBD
System
— Check —
9 1. Disconnect the injector test connector.
2. At the injector side of the harness, connect an
ohmmeter between the positive wire (red with blue
tracer) and the wire for cylinder 1 (green with white
tracer).
Does the ohmmeter indicate continuity? — Go to Step 11 Go to Step 10
10 Repair the open injector harness wire or open injector.
11 At the PCM side of the injector test connector, check
the green/white wire for a short to voltage.
Was there a short to voltage? — Go to Step 12 Go to Step 13
12 Repair the short to voltage.
13 Check for an open circuit between the injector test
connector and the PCM.
14 Repair the open circuit.
15 Replace the PCM.
procedures.
D06RY00086

injector driver circuits. Each controls an injector. When a consecutive trip cycle in which the diagnostic has been
driver circuit is grounded by the PCM, the injector is run and the fault is no longer present.
circuit.
Diagnostic Aids
Test Description
tethered to the wiring harness. If the light for 9.The reading should be about 12-14W.
access.
R321055

performed? System
Cranks But
Will Not Run
parameters.

2. Disconnect the injector test connector.
3. Install an injector test light J-39021-65 on injector
connector. Go to Fuel
Injector Coil
Does the cylinder 2 test light blink? — Procedure Go to Step 6
injectors.
System
— Check —
tracer) and the wire for cylinder 2 (green with orange
tracer).
the green/orange wire for a short to voltage.
15 Replace the PCM.
procedures.
D06RY00086

injector driver circuits. Each controls an injector. When consecutive trip cycle in which the diagnostic has been
the driver circuit is grounded by the PCM, the injector is run and the fault is no longer present.
circuit.
Diagnostic Aids
D The engine is turning, determined by the 58X
crankshaft position input signal. set indicating which cylinder is inoperative.
Test Description
access.
R321056

performed? System
Cranks But
Will Not Run
parameters.

2. Disconnect the injector test connector .
Injector Coil
injectors.
System
— Check —
tracer) and the wire for cylinder 3 (green).
the green wire for a short to voltage.
15 Replace the PCM.
procedures.
D06RY00086

circuit.
Diagnostic Aids
crankshaft position input signal. set indicating which cylinder is inoperative.
Test Description
access.
R321057

performed? System
Cranks But
Will Not Run
parameters.

Injector Coil
injectors.
System
— Check —
tracer) and the wire for cylinder 4 (green/red).
the green/red wire for a short to voltage.
15 Replace the PCM.
procedures.
D06RY00086

circuit. If the voltage is not what the PCM expects to warm-up cycles occur without a fault.
monitor on the circuit, a DTC is set. This DTC is also set if D DTC P0205 can be cleared by using the Tech 2 “Clear
an injector driver is shorted to voltage or if there is an open Info” function or by disconnecting the PCM battery
circuit. feed.
Conditions for Setting the DTC Diagnostic Aids

D The battery voltage is more than 9 volts. An injector driver circuit that is open or shorted to voltage
will cause a DTC P0205 to set. It will also cause a misfire
crankshaft position input signal. due to an inoperative injector. A misfire DTC will also be
set indicating which cylinder is inoperative.
when the injector is commanded “OFF” or the injector Long term and short term fuel trims that are excessively
voltage does not equal 0 volts when the injector is high or low are a good indication that an injector is faulty.
commanded “ON.” Use Fuel Injector Coil Test Procedure to check for faulty
D The above conditions are met for 15 seconds. injectors.
Action Taken When the DTC Sets Test Description

D The PCM will illuminate the malfunction indicator lamp The number(s) below refer to the step number(s) on the
(MIL) the first time the fault is detected. Diagnostic Chart.
D The PCM will store conditions which were present 3. This step determines if DTC P0205 is the result of a
when the DTC was set as Freeze Frame and in the hard failure or an intermittent condition.
removal of the manifold.The test connector can be at all times. This step determines if the circuit is
access.
R321058

performed? System
Cranks But
Will Not Run
parameters.

Injector Coil
injectors.
System
— Check —
tracer) and the wire for cylinder 5 (green with black
tracer).
the green/black wire for a short to voltage.
15 Replace the PCM.
procedures.
D06RY00086

circuit.
Diagnostic Aids
Test Description
removal of the manifold.The test connector can be at all times. This step determines if the circuit is
access.
R321059

performed? System
Cranks But
Will Not Run
parameters.

Injector Coil
injectors.
System
— Check —
tracer) and the wire for cylinder 6 (green with yellow
tracer).
10 Repair the open injector harness wire or open injector
the green/yellow wire for a short to voltage.
15 Replace the PCM.
procedures.
Diagnostic Trouble Code (DTC) P0300 Engine Misfire Detected

Circuit Description D Damaged or faulty ignition coil – Check for cracks or
other damage.
Misfire is monitored as a function of the combustion
quality (CQ) signals generated from the ION Sensing D Substitute a known good coil – Swap the ignition coils
and retest. If the misfire follows the coil, replace the
Module system. Combustion signals represent the ignition coil.
degree of combustion in each cylinder. Misfire is detected If the misfire is random, check for the following conditions:
when the combustion signal is below a predetermined
D System grounds – Ensure all connections are clean
value. and properly tightened.
This DTC P0300 will determine if a multiple cylinder
D MAF – A mass air flow (MAF) sensor output that
misfire is occurring by monitoring the Combustion causes the PCM to sense a lower than normal air flow
Quality. will cause a lean condition.
D Air induction system – Air leaks into the induction
Conditions for Setting the DTC system which bypass the MAF sensor will cause a lean
D None of the following DTCs occur: TP sensor, MAF condition. Check for disconnected or damaged
sensor, VSS, ECT sensor. vacuum hoses, incorrectly installed or faulty PCV
valve, or for vacuum leaks at the throttle body, EGR
D The engine speed is between 600 and 6250 RPM. valve, and intake manifold mounting surfaces.
D The system voltage is between 11 and 16 volts. D Fuel pressure – Perform a fuel system pressure test.
D The engine temperature sensor (ECT) indicates an A faulty fuel pump, plugged filter, or faulty fuel system
engine temperature between –7°C (20°F) and 120°C pressure regulator will contribute to a lean condition.
(248°F). D Injector(s) – Perform an injector coil/balance test to
D Throttle angle is steady and throttle changes less than locate faulty injector(s) contributing to a lean or
15% per 125 milliseconds. flooding condition. In addition to the above test, check
the condition of the injector O-rings.
Action Taken When the DTC Sets D EGR – Check for a leaking valve, adapter, or feed pipes
D The PCM will illuminate the malfunction indicator lamp which will contribute to a lean condition or excessive
(MIL) the first time the fault is detected. EGR flow.
D If the misfire is severe enough to cause possible D Fuel quality – Using fuel with the wrong octane rating
catalyst damage, the PCM will flash the MIL for as long for the vehicle may cause driveability problems.
as the misfire remains at catalyst damaging levels. Although alcohol-enhanced fuels may raise the octane
rating, the fuel’s ability to turn into vapor in cold
D The PCM will disable the TCC operation. temperatures deteriorates. This may affect the cold
D The PCM will store conditions which were present driveability of the engine. The Reid Vapor Pressure of
when the DTC was set as Freeze Frame and in the the fuel can also create problems in the fuel system,
Failure Records data. especially during the spring and fall when changes by
the refineries may not coincide with changes in the
Conditions for Clearing the MIL/DTC weather.
D The PCM will turn the MIL “OFF” on the third D Vehicle marshalling – The transportation of new
consecutive trip cycle in which the diagnostic has been vehicles from the assembly plant to the dealership can
run and the fault condition is no longer present. involve as many as 60 key cycles within 2 to 3 miles of
driving. This type of operation contributes to the fuel
D A history DTC P0300 will clear after 40 consecutive fouling of the spark plugs and will turn on the MIL with
warm-up cycles occur without a fault. a P0300 Misfire DTC.
D DTC P0300 can be cleared by using the Tech 2 “Clear Reviewing the Failure Records vehicle mileage since the
Info” function or by disconnecting the PCM battery diagnostic test last failed may help determine how often
feed.
Diagnostic Aids may assist in diagnosing the condition.
The Tech 2 display “Misfire Cur. #1 through #6” can be
useful to determine whether the misfire is isolated to a
single cylinder.
DTC P0300 – Engine Misfire Detected

performed? System
2 1. Start the engine. Run the engine at idle.
2. Review and record the Tech 2 Freeze Frame data.
3. Operate the vehicle to duplicate the conditions
present when the DTC was set (as defined by the
Freeze Frame data).
4. Monitor the Tech 2 “Misfire Cur. #” display for each
cylinder. Refer to
Is “Misfire Cur. #” display increasing for any cylinder Diagnostic
(indicating a misfire currently occurring)? — Go to Step 3 Aids
3 1. Visually and physically inspect the vacuum hoses
for splits, kinks, and improper connections.
2. If a problem is found, repair or replace the vacuum
hoses as necessary.
4 1. Visually and physically inspect the following areas
for vacuum leaks:
D The intake manifold
D The injector O-rings
D The EGR adapter
D The EGR feed pipes
D ION Sensing Module
2. If a problem is found, repair the vacuum leak as
necessary.
5 1. Visually and physically inspect the crankcase
ventilation valve for improper installation or
damaged grommet.
2. If a problem is found, repair as necessary (refer to
Crankcase Ventilation System).
for the presence of foreign objects that may partially
block the air flow sample through the MAF sensor.
2. If a problem is found, repair or replace the MAF
sensor as necessary.
7 1. Remove the EGR valve and visually/physically
inspect the valve to ensure that the pintle is not
sticking partially open. Also, inspect the EGR valve
pintle and seat for carbon deposits or burrs that may
interfere with the pintle closing completely.
2. If a problem is found, clean the EGR valve pintle and
seat or replace the EGR valve as necessary.
DTC P0300 – Engine Misfire Detected (Cont'd)

8 1. Install a spark tester at the spark plug end of the
ignition coil for a cylinder that indicated a misfire.
2. Crank the engine while observing the spark tester.
A crisp, blue spark should be observed.
Is adequate spark present? — Go to Step 14 Go to Step 9
9 1. Remove and visually/physically inspect the ignition
coil(s) associated with the cylinders that were
indicated as misfiring. Ensure that the coil(s) are
free of cracks.
2. If a problem is found, replace the damaged ignition
coil(s) as necessary.
Did any ignition coils require replacement? — Verify repair Go to Step 10
10 1. Remove the spark plugs from the cylinders that
were indicated as misfiring.
2. Visually inspect the spark plug electrodes. Go to Engine
Does your inspection reveal any spark plugs exhibiting Mechanical
excessive fouling? — Diagnosis Go to Step 11
11 1. Visually inspect the spark plug insulators for cracks,
carbon tracking, or other damage.
2. If a problem is found, replace the faulty spark
plug(s) as necessary.
12 1. Disconnect the MAF sensor electrical connector. ”BANK 1 L.T.
2. Operate the vehicle in “closed loop” while FUEL TRIM”
monitoring the “BANK 1 L.T. FUEL TRIM” and below +20%; Replace the
“BANK 1 S.T. FUEL TRIM” display on the Tech 2. “BANK 1 S.T. ignition coil of
Do both values decrease below the specified values? FUEL TRIM” the affected
below +50% Go to Step 13 cylinder
13 Replace the ignition coil control module.
ensure that they are clean, tight and in their proper
locations.
2. If a problem is found, correct the faulty ground
condition as necessary.
Did your inspection reveal a poor ground? — Verify repair Go to Step 15
15 1. Perform the “Fuel System Pressure Test”
procedure.
2. If a problem is found, repair as necessary (refer to
Engine Fuel or Fuel Metering System).
Was a fuel system problem found? — Verify repair Go to Step 16
16 1. Check the fuel for excessive water, alcohol, or other
contaminants (refer to Diagnosis in Engine Fuel for
procedure).
2. If a problem is found, correct the contaminated fuel
condition as necessary.
DTC P0300 – Engine Misfire Detected (Cont'd)

17 1. Perform the “Injector Coil/Balance Test.”
2. If a problem is found, replace faulty injector(s) as
necessary.
Did any of the injectors require replacement? — Verify repair Go to Step 18
18 1. Check for an engine mechanical problem. Refer to
Engine Mechanical Diagnosis to diagnose the
D A faulty or incorrect camshaft
D A leaking head gasket
D A loose or broken motor mount
Was a basic engine mechanical problem found and
repaired? — Verify repair Go to Step 19
19 1. Check for a transmission TCC problem. Refer to
4L30-E Automatic Transmission Diagnosis.
2. If a problem is found, repair the transmission as
necessary. Refer to 4L30-E Automatic
Transmission Unit Repair.
Was a transmission problem found and repaired? — Verify repair Go to Step 20
Diagnostic Trouble Code (DTC) P0301 Cylinder Misfire Detected

Misfire is monitored as a function of the combustion D The PCM will turn the MIL “OFF” on the third
quality (CQ) signals generated from the ignition current consecutive ignition cycle in which the diagnostic has
sense system. Combustion signals represent the degree been run and the fault condition is no longer present.
of combustion in each cylinder. Misfire is detected when D A history DTC P0301 will clear after 40 consecutive
the combustion signal is below a predetermined value. ignition cycles occur without a fault.
This DTC P0301 will determine if the No.1 cylinder misfire D DTC P0301 can be cleared by using the Tech 2 “Clear
is occurring by monitoring the Combustion Quality. Info” function or by disconnecting the PCM battery
feed.
Diagnostic Aids
D None of the following DTCs occur: TP sensor, MAF
sensor, vehicle speed sensor, ECT sensor. Check for the following conditions:
D The engine speed is between 600 and 6250 RPM. D System grounds – Ensure all connections are clean
and properly tightened.
D The system voltage is between 11 and 16 volts.
D Injector – Perform the injector coil/balance test to
D The ECT indicates an engine temperature between locate a faulty injector that contributes to a lean
–7°C (28°F) and 120°C (248°F). condition on the affected cylinder. In addition to the
D The throttle angle is steady. above test, check the condition of the injector O-ring.
D Faulty spark plug – Check for a cracked insulator,
Action Taken When the DTC Sets carbon tracking, incorrect gap, and worn electrodes.
D The PCM will illuminate the malfunction indicator lamp D Damaged or faulty ignition coil – Check for cracks or
(MIL) the first time the fault is detected. other damage.
D If the misfire is severe enough to cause possible D Substitute a known good coil – Swap the ignition coils
catalyst damage, the PCM will flash the MIL for as long and retest. If the misfire follows the coil, replace the
as the misfire remains at catalyst damaging levels. ignition coil.
DTC P0301 – Cylinder Misfire Detected

performed? System
2. Review and record Tech 2 Freeze Frame data.
3. Monitor “Misfire Cur. #1” on the Tech 2.
Is “Misfire Cur. #1” increasing (indicating a misfire
currently occurring)? — Go to Step 4 Go to Step 3
3 Monitor “Misfire Hist. #1” while operating the vehicle to
duplicate the conditions present when the DTC was set
(as defined by the Freeze Frame data recorded in Step
2).
Refer to
Is “Misfire Hist. #1” increasing (indicating a misfire Diagnostic
currently occurring)? — Go to Step 4 Aids
for splits, kinks, and improper connections. Also,
inspect the intake manifold for a vacuum leak.
2. If a problem is found, repair it as necessary.
Did the inspection reveal a problem? — Verify repair Go to Step 5
cylinder #1 ignition coil.
DTC P0301 – Cylinder Misfire Detected (Cont'd)

coil associated with cylinder #1. Ensure that the coil
is free of cracks and carbon tracking.
coil as necessary.
Did the visual inspection reveal a problem? — Verify repair Go to Step 7
7 1. Measure the ignition coil primary resistance.
2. If resistance is not within the specified value,
replace the faulty ignition coil.
Did the ignition coil require replacement? 2.6-2.7 KW Verify repair Go to Step 12
8 Remove the cylinder #1 spark plug and visually inspect Go to
the spark plug electrode. Contaminatio
n Diagnosis
Does the inspection reveal excessive fouling?
chart in
Engine
Mechanical
— Diagnosis Go to Step 9
9 1. Visually inspect the spark plug insulator for cracks,
2. If the spark plug is damaged, replace the spark plug.
2. If any faulty injectors are found, replace them as
necessary.
11 1. Inspect the injector O-rings for a vacuum leak.
12 Check for an engine mechanical problem. Refer to
Engine Mechanical Diagnosis to diagnose and repair
the following conditions:
Refer to
Diagnostic
Was a basic engine mechanical problem found? — Verify repair Aids

feed.
Diagnostic Aids
D The PCM will illuminate the malfunction indicator lamp D Damaged or faulty ignition coil – Check for cracks,
(MIL) the first time the fault is detected. carbon tracking or other damage.

performed? System
2).
Refer to

coil as necessary.
n Diagnosis
chart in
Engine
Mechanical
necessary.
Refer to
Diagnostic

feed.
Diagnostic Aids
D Injector — Perform the injector coil/balance test to

performed? System
2).
Refer to

coil as necessary.
n Diagnosis
chart in
Engine
Mechanical
necessary.
Refer to
Diagnostic

feed.
Diagnostic Aids

performed? System
2).
Refer to
cylinder #4 ignition wire.

coil as necessary.
n Diagnosis
chart in
Engine
Mechanical
necessary.
Refer to
Diagnostic

feed.
Diagnostic Aids

performed? System
2).
Refer to

coil as necessary.
n Diagnosis
chart in
Engine
Mechanical
necessary.
Refer to
Diagnostic

feed.
Diagnostic Aids
D None of the following occur: TP sensor, MAF sensor,
vehicle speed sensor, ECT sensor. Check for the following conditions:
D The PCM will illuminate the malfunction indicator lamp D Damaged or faulty ignition coil – Check for cracks or
(MIL) the first time the fault is detected. other damage.

performed? System
2).
Refer to

coil as necessary.
n Diagnosis
chart in
Engine
Mechanical
necessary.
11 1. Inspect the intake manifold and the injector O-rings
for a vacuum leak.
Refer to
Diagnostic
Diagnostic Trouble Code (DTC) P0325 ION Sensing Module/ION Sensing

Knock Intensity Circuit Fault
D06RY00067

The Power Control Module (PCM) checks the validity of D The PCM will turn the MIL “OFF” on the third
the signals used in the ION Sensing module at the consecutive trip cycle during which the diagnostic has
following engine opreating conditions. been run and the fault condtion is no longer present.
D The test is performed to evauate the Knock Intensity D A history DTC P0325 will clear after 40 cosecutive trip
(KI) signal pulse width if it is within a predetermined cycle during which the warm up cycles have occurred
renge. If the KI signal puls width is out of the without a fault.
predetermined range, the fail counter will be D DTC P0325 can be cleared using the Tech2 “Clear
incremented. If the failure counter excceds the Info” function or by disconnecting the PCM battery
calibration, then test is complete and a failure will be feed.
reported. If the sample counter threshold is reached
before the failure threshold, then the test is complete Diagnostic Aids
and a pass will be reported. This test will detect an
open/short in the KI line circuit, ION module faults and An intermittent may be caused by the following:
analog input faults in the PCM. D Poor connectons.
Conditions for setting the DTC D Rubbed through wire insulation.
D Ignition voltage is between 10volt and 16 volts. D Broken wire inside the insulation.
D No Crank DTCs set. Check for the following conditions:
D No EST DTCs. D Poor connection at PCM- Inspect harness connectors
for backed out terminals, improper mating, broken
Action Taken When the DTC Sets locks, improperly formed or damaged terminals, and
poor terminal to wire connection.
(MIL) the first time the fault is detected. D Damaged harness-Inspect the wiring harness for
damage.
D The PCM calculates an air flow value based on idle air
control valve position, throttle position, RPM and If the harness appears to be OK, observe the
barometric pressure. Knock Present, Knock Sensor Noise Channel
D The PCM will store condition which were present when display on the Tech 2 while moving connectors
the DTC was set as Freeze Frame and in the Failure and wiring harnesses related to the sensor.
Records data.
A change in the display will indicate the location of If it is determined that the DTC occurs
the fault. intermittently, performing the DTC P0325
If DTC P0325 cannot be duplicated, the Diagnostic Chart may isolate the cause of the
information included in the Faillure Records data fault.
DTC P0325 - ION Sensing Module Knock Intensity Circuit Fault

System
Does the Tech 2 indicate DTC P0325 failed Diagnostic
thisignition? — Go to Step 3 Aids
2. Disconnect the ION sensing module.
4 Check the ION sensing harness between the PCM
(F68) and ION sensing module circuit (RED Wire) at
the KI line harness connector.
5 1. Disconnect the ignition coil.
6 Check the ION sensing harness between the ignition
coil and ION sensing module circuit at the DC motor
harness connector.
7 Check the following items;
1. Ignition coil and ignition coil circuit.
2. Ignition coil ground circuit for a poor connection.
3. If a problem is found,repair wiring harness as
necessary.
8 Replace the Ignition coil.
1. ION sensing module ground circuit for a poor
connection.
necessary.
DTC P0325 - ION Sensing Module Knock Intensity Circuit Fault (Cont'd)
10 Replace the ION Sensing module.
11 Replace the PCM.
programmed.
And also refer to latest Service Bulletin. Check to see if
the latest software is released or not .And then Down
Load the LATEST PROGRAMMED SOFTWARE to
the replasement PCM.
Diagnostic Trouble Code (DTC) P0336 58X Reference Signal Circuit
D06RY00066

The 58X reference signal is produced by the crankshaft D The PCM will illuminate the malfunction indicator lamp
position (CKP) sensor. During one crankshaft revolution, (MIL) after the second consecutive trip in which the
58 crankshaft pulses will be produced. The powertrain fault is detected.
control module (PCM) uses the 58X reference signal to D The PCM will store conditions which were present
calculate engine RPM and crankshaft position. The PCM when the DTC was set as Freeze Frame and in the
constantly monitors the number of pulses on the 58X Failure Records data.
reference circuit and compares them to the number of
camshaft position (CMP) signal pulses being received. If Conditions for Clearing the MIL/DTC
the PCM receives an incorrect number of pulses on the D The PCM will turn the MIL “OFF” on the third
58X reference circuit, DTC P0336 will set. consecutive trip cycle during which the diagnostic has
Conditions for Setting the DTC D A history DTC P0336 will clear after 40 consecutive
warm–up cycles have occurred without a fault.
D Engine is running.
D Extra or missing pulse is detected between Info” function or by disconnecting the PCM battery
consecutive 58X reference pulses. feed.
D Above condition is detected in 10 of 100 crankshaft
rotations.
Diagnostic Aids
rubbed-through wire insulation or a wire broken inside the
insulation. Check for:
D Poor connection - Inspect the PCM harness and
connectors for improper mating, broken locks,
improperly formed or damaged terminals, and poor
terminal-to-wire connection.
damage. If the harness appears to be OK, disconnect
the PCM, turn the ignition on and observe a voltmeter
connected to the 58X reference circuit at the PCM
harness connector while moving connectors and
wiring harnesses related to the PCM. A change in
voltage will indicate the location of the fault.
DTC P0336 – 58X Reference Signal Circuit

performed? System
2 Attempt to start the engine. Go to “Engine
Cranks But
Does the engine start?
Will Not Run”
3 1. Review and record Failure Records information.
2. Clear DTC P0336.
Refer to
4. Observe DTCs. Diagnostic
Is DTC P0336 set? — Go to Step 4 Aids
4 1. Disconnect the PCM and CKP sensor.
2. Check for an open or a short to ground in the 58X
reference circuit between the CKP sensor
connector and the PCM harness connector.
5 1. Reconnect the PCM and CKP sensor.
2. Connect a DVM to measure voltage on the 58X
reference circuit at the PCM connector.
3. Observe the voltage while cranking the engine.
Is the voltage near the specified value? 2.5 V Go to Step 8 Go to Step 6
6 Check the connections at the CKP sensor and replace
the terminals if necessary.
7 Replace the CKP sensor. Use caution to avoid any hot
oil that may drip out.
8 Check connections at the PCM and replace the
terminals if necessary.
9 Replace the PCM.
procedures.
Diagnostic Trouble Code (DTC) P0337 CKP Sensor Circuit Low Frequency
D06RY00066
Circuit Description D CKP reference pulse is not detected within 8 CMP

pulses.
The 58X reference signal is produced by the crankshaft
position (CKP) sensor. During one crankshaft revolution, Action Taken When the DTC Sets
58 crankshaft reference pulses will be produced. The
powertrain control module (PCM) uses the 58X reference D The PCM will illuminate the malfunction indicator lamp
signal to calculate engine RPM and crankshaft position. (MIL) after the second consecutive trip in which the
fault is detected.
The PCM constantly monitors the number of pulses on
the 58X reference circuit and compares them to the D The PCM will store conditions which were present
number of camshaft position (CMP) signal pulses being Failure Records data.
received. If the PCM does not receive pulses on the 58X
reference circuit, DTC P0337 will set. Conditions for Clearing the MIL/DTC
D No camshaft position (CMP) sensor DTCs are set. been run and the fault condition is no longer present.
D Engine cranking. D A history DTC P0337 will clear after 40 consecutive
D Crankshaft position (CKP) sensor signal is not present warm-up cycles have occurred without a fault.
between two cam pulses.
D DTC P0337 can be cleared by using the Tech 2 “Clear D Damaged harness – Inspect the wiring harness for
Info” function or by disconnecting the PCM battery damage. If the harness appears to be OK, disconnect
feed. the PCM, turn the ignition on and observe a voltmeter
connected to the 58X reference circuit at the PCM
Diagnostic Aids harness connector while moving connectors and
wiring harnesses related to the PCM. A change in
An intermittent may be caused by a poor connection, voltage will indicate the location of the fault.
rubbed-through wire insulation or a wire broken inside the Reviewing the Failure Records vehicle mileage since the
insulation. Check for: diagnostic test last failed may help determine how often
D Poor connection – Inspect the PCM harness and the condition that caused the DTC to be set occurs. This
connectors for improper mating, broken locks, may assist in diagnosing the condition.
DTC P0337 – CKP Sensor Circuit Low Frequency

performed? System
Does the engine start? — Go to Step 3 Go to Chart 3
3 1. Review and record Failure Records information.
2. Clear DTC P0337.
Refer to
4. Observe DTCs. Diagnostic
Is DTC P0337 set? — Go to Step 4 Aid
4 1. Disconnect the CKP sensor.
3. Using a DVM, verify that 5 V reference and ground
are being supplied at the sensor connector (PCM
side).
Are 4-6 volts and ground available at the sensor? — Go to Step 7 Go to Step 5
2. With a DVM, backprobe the PCM connector 5 V
reference and ground connections.
Are 5 V reference and ground available at the PCM? — Go to Step 6 Go to Step 11
6 Check 5 V reference or ground between the CKP
sensor and PCM and repair the open circuit, short to
ground or short to voltage.
2. Disconnect the PCM and CKP sensor.
3. Check for an open or a short to ground in the 58X
reference circuit between the CKP sensor
connector and the PCM harness connector.
8 1. Reconnect the PCM and CKP sensor.
2. Connect a DVM to measure voltage on the 58X
reference circuit at the PCM connector.
3. Observe the voltage while cranking the engine.
Is the voltage near the specified value? 2.5 V Go to Step 11 Go to Step 9
DTC P0337 – CKP Sensor Circuit Low Frequency (Cont'd)

9 Check the connections at the CKP sensor and replace
the terminals if necessary.
10 Replace the CKP sensor. Use caution and avoid hot oil
that may drip out.
11 Check the connections at the PCM and replace the
terminals if necessary.
12 Replace the PCM.
procedures.
Diagnostic Trouble Code (DTC) P0341 CMP Sensor Circuit Performance
D06RY00066
Circuit Description Conditions for Setting the DTC

The CMP signal is produced by the camshaft position D The engine is running (1X CMP reference pulses are
(CMP) sensor pulses when the engine is running and being received).
crankshaft position (CKP) sync pulses are also being D The CMP sensor signal is not detected at the correct
received. The powertrain control module (PCM) uses the interval every 6 cylinders.
CMP signal pulses to initiate sequential fuel injection. D Above condition fails for 100 occurrences within 200
The PCM constantly monitors the number of pulses on test samples.
the CMP signal circuit and compares the number of CMP
pulses to the number of 58X reference pulses received. If Action Taken When the DTC Sets
the PCM receives an incorrect number of pulses on the D The PCM will illuminate the malfunction indicator lamp
CMP reference circuit, DTC P0341 will set and the PCM (MIL) after the second consecutive trip in which the
will initiate injector sequence without the CMP signal with fault is detected.
a one in six chance that injector sequence is correct. The D The PCM will initiate the injector sequence without the
engine will continue to start and run normally, although CMP signal with a one in six chance that the injector
the misfire diagnostic will be affected if a misfiring sequence is correct.
condition occurs. D The PCM will store conditions which were present
feed.
Diagnostic Aids
insulation. Check for:
D Poor connection – Inspect the PCM harness and
connectors for improper mating, broken locks,
the PCM, turn the ignition on and observe a voltmeter
connected to the CMP signal circuit at the PCM
harness connector while moving connectors and
wiring harnesses related to the PCM and the CMP
sensor. A change in voltage will indicate the location
of the fault.
Test Description
Diagnostic Chart.
2. Ensures that the fault is present.
12.Determines whether the fault is being caused by a
missing camshaft magnet or a faulty sensor. The
voltage measured in this step should read around 4
volts, toggling to near 0 volts when the CMP sensor
interfaces with the camshaft magnet.
DTC P0341 – CMP Sensor Circuit Performance

performed? System
3 1. Disconnect the CMP sensor.
2. Measure the voltage between the sensor feed
circuit and the sensor ground circuit at the CMP
sensor harness connector.
Does the voltage measure near the specified value? 4-6 V Go to Step 4 Go to Step 5
4 Measure the voltage between the CMP sensor signal
circuit and the sensor ground circuit at the CMP sensor
harness connector.
5 If the voltage measured in step 3 was less than 4-6
volts, proceed directly to step 6 without completing this
step.
If the voltage in step 3 was greater than 4-6 V, repair the
short to voltage in the CMP feed circuit.
6 1. Check for poor connections at the camshaft
position sensor.
7 1. Ignition “OFF,” disconnect the PCM and the CMP
sensor.
2. Check the following circuits for an open between the
ignition control module and the CMP sensor:
D The sensor feed circuit.
8 1. Ignition “OFF,” disconnect the PCM (leave the CMP
sensor disconnected).
2. Ignition “ON,” check the following circuits:
D The CMP sensor signal circuit for an open or a
short to voltage.
D The CMP sensor input signal circuit for a short
to ground.
9 Check for a short or open in the sensor ground circuit.
DTC P0341 – CMP Sensor Circuit Performance (Cont'd)

10 1. Check for poor connections at the PCM.
11 Backprobe the PCM connector with a DVM to monitor
voltage on the camshaft position input signal circuit
while cranking the engine with the sensor connected.
(Use rubber band, tape, or an assistant to keep the
DVM lead in contact with the sensor terminal during this
test.)
Does the voltage toggle between the specified values? 4-0 V Go to Step 15 Go to Step 12
12 1. Remove the CMP sensor.
2. Place a magnet on the CMP sensor.
(If you use a magnet that is too small to cover the face
of the sensor, test on every part of the sensor face
because only a small area will respond to this test.)
Does the DVM display a voltage near the specified
value? 0V Go to Step 13 Go to Step 14
13 Replace the faulty or missing camshaft position sensor
magnet.
14 Replace the camshaft position sensor.
15 Replace the PCM.
procedures.
Diagnostic Trouble Code (DTC) P0342 CMP Sensor Circuit Low
D06RY00066

The CMP signal produced by the camshaft position D The engine is running.
(CMP) sensor pulses when the engine is running and D The CMP sensor signal is not received by the PCM
crankshaft position (CKP) sync pulses are also being once every 6 cylinders.
received. The hall type CMP sensor and the CKP sensor D The above condition occurs for 10 seconds.
share 5 V and ground connections at the powertrain
control module (PCM). The third wire at the sensor is a Action Taken When the DTC Sets
signal circuit to the PCM. The PCM uses the CMP signal
pulses to initiate sequential fuel injection. The PCM (MIL) after the second consecutive trip in which the
constantly monitors the number of pulses on the CMP fault is detected.
signal circuit and compares the number of CMP pulses to D The PCM will initiate injector sequence without the
the number of 58X reference pulses received. If the PCM CMP signal with a one in six chance that the injector
does not receive pulses on the CMP reference circuit, sequence is correct.
DTC P0342 will set and the PCM will initiate injector D The PCM will store conditions which were present
sequence without the CMP signal with a one in six chance when the DTC was set as Freeze Frame and in the
that injector sequence is correct. The engine will continue Failure Records data.
to start and run normally, although the misfire diagnostic
will be affected if a misfiring condition occurs.
Conditions for Clearing the MIL/DTC D Damaged harness – Inspect the wiring harness for
D The PCM will turn the MIL “OFF” on the third the PCM, turn the ignition on and observe a voltmeter
consecutive trip cycle during which the diagnostic has connected to the CMP signal circuit at the PCM
been run and the fault condition is no longer present. harness connector while moving connectors and
D A history DTC P0342 will clear after 40 consecutive wiring harnesses related to the PCM and the CMP
warm-up cycles have occurred without a fault. sensor. A change in voltage will indicate the location
D DTC P0342 can be cleared by using the Tech 2 “Clear of the fault.
feed. Test Description
Diagnostic Aids Diagnostic Chart.
An intermittent may be caused by a poor connection, 2. Ensures that the fault is present.
14.Determines whether the fault is being caused by a
insulation. Check for: damaged camshaft or a faulty PCM. The voltage
D Poor connection – Inspect the PCM harness and measured in this step should read around 4 volts,
connectors for improper mating, broken locks, toggling to near 0 volts when the CMP sensor
improperly formed or damaged terminals, and poor interfaces with the camshaft magnet.
terminal to wire connection.
DTC P0342 – CMP Sensor Circuit Low

performed? System
4. Using a Tech 2, monitor “DTC” information for DTC
P0342 until the DTC P0342 test runs.
5. Note test result. Refer to
2. Disconnect the CMP sensor.
3. Measure the voltage between the sensor feed
circuit and the sensor ground circuit at the CMP
4 1. Ignition “OFF,” disconnect the PCM and the CMP
sensor.
2. Check for poor connections at the camshaft
position sensor.
5 1. Check for poor connections at the PCM.
DTC P0342 – CMP Sensor Circuit Low (Cont'd)

6 1. Check the following circuits between the PCM and
the CMP sensor:
D The sensor feed circuit. Open or short to
ground?
D The sensor ground circuit. Open or short to
voltage?
2. Measure the voltage between the CMP sensor
signal circuit and the sensor ground circuit at the
CMP sensor harness connector.
2. Disconnect the PCM and connect a DVM to monitor
voltage on the camshaft position signal circuit at the
PCM connector.
4. Monitor the voltage display on the DVM while
repeatedly touching the CMP sensor signal circuit
at the CMP sensor connector with a test light to
ground.
Does the DVM voltage display switch between 0 and
approximately 5 volts when the test light is touched to
the CMP sensor signal circuit? — Go to Step 12 Go to Step 9
2. Leave the PCM disconnected.
4. Probe the camshaft position signal circuit at the
PCM connector with a test light to B+.
5. If the test light is “ON,” locate and repair the short to
ground in the camshaft position input signal circuit.
Was either circuit shorted to ground? — Verify repair Go to Step 10
2. Leave the PCM disconnected.
4. Probe the camshaft position signal circuit with a test
light to ground.
5. If the test light is “ON,” locate and repair the short to
voltage in the camshaft position input signal circuit.
Was the test light “ON”? — Verify repair Go to Step 11
11 1. Ignition “OFF,” disconnect the PCM (leave the CMP
sensor disconnected).
2. Ignition “ON,” check the following circuit:
D The CMP sensor signal circuit for an open.
DTC P0342 – CMP Sensor Circuit Low (Cont'd)

2. Remove the CMP sensor.
3. Place a magnet on the CMP sensor. If you use a
magnet that is too small to cover the face of the
sensor, test on every part of the sensor face
because only a small area will respond to this test.
Does the DVM display a voltage near the specified
13 Replace the camshaft position sensor.
14 Replace the PCM.
procedures.
Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit
D06RY00067
Circuit Description D The output voltage is not equal to 0 volts when output
is “OFF.”
ION Sensing Module has the function to energize and
de-energize the primary ignition coil in response to D Ten test failures occur within 10 samples of continuous
spark events.
signals from the PCM. The PCM controls ignition timing
and dwell time. Action Taken When the DTC Sets
This diagnosis detects open circuit or short-circuiting in
the Ignition Electronic Spark Timing (EST) line by D The PCM will illuminate the malfunction indicator lamp
monitoring EST signals. A failure determination is made (MIL) the first time the fault is detected.
when the signal voltage remains higher or lower than the D The PCM will store conditions which were present
threshold for corresponding fault code beyond a when the DTC was set as Freeze Frame and in the
predetermined time period.
When the PCM detects a problem on EST control circuit Conditions for Clearing the MIL/DTC
1, it will set a DTC P0351.
Conditions for Setting the DTC consecutive trip cycle in which the diagnostic has been
run and the fault condition is no longer present.
D The ignition is “ON.” D A history DTC P0351 will clear after 40 consecutive
D The engine is turning, determined by the 58X warm-up cycles occur without a fault.
crankshaft position input signal. D DTC P0351 can be cleared by using the Tech 2 “Clear
D The output voltage is not equal to 5 volts when output Info” function or by disconnecting the PCM battery
is “ON.” feed.
Diagnostic Aids Tech 2 display related to DTC P0351 while moving the
connector and wiring related to the ignition system. A
Check for the following conditions: change in the display will indicate the location of the
D Poor connection at PCM – Inspect the harness fault.
connectors for backed-out terminals, improper mating, Reviewing the Failure Records vehicle mileage since the
broken locks, improperly formed or damaged diagnostic test last failed may help determine how often
terminals, and poor terminal-to-wire connections.
D Damaged harness – Inspect the wiring harness for may assist in diagnosing the condition.
DTC P0351 – Ignition 1 Control Circuit

performed? System
3. Operate the vehicle within Failure Record
4. Use a Tech 2 to monitor the “DTC” information for
DTC P0351 until the DTC P0351 test runs.
5. Note the test result. Go to
Does the Tech 2 indicate DTC P0351 failed this ignition Diagnostic
cycle? — Go to Step 3 Aids
3 Check for faulty connection at ignition coil.
4 Check for faulty connection at PCM connector.
2. Back probe the ignition control circuit 1 at the ION
Sensing Module with a DVM.
Is the voltage near the specified value? 25-55 mV Go to Step 6 Go to Step 9
6 1. Ignition “ON,” engine running.
2. Back probe the ignition control circuit at the ION
Sensing Module for the cylinder being tested.
Is the voltage in the specified range, rapidly toggling
back and forth to a reading 20-50 mV higher? 100-180 mV Go to Step 7 Go to Step 13
2. Disconnect the 3-pin and connector at the ignition
coil.
3. Check ignition control circuit 1 voltage at the ignition
coil connector while cranking the engine.
Does the voltage measure between the specified
values? 200-1200 mV Go to Step 8 Go to Step 11
8 Replace the ignition coil.
2. Disconnect the PCM and the ignition coil.
3. Check ignition control circuit 1 for short to ground.
10 Check ignition control circuit 1 for short to voltage.
DTC P0351 – Ignition 1 Control Circuit (Cont'd)

11 Check for an open ignition control circuit 1.
Was the ignition control circuit open? — Go to Step 12 Go to Step 13
12 Repair the open ignition control circuit.
13 Replace the PCM.
procedures.
D06RY00067
is “OFF.”
spark events.
D The engine is turning, determined by the 58 X warm-up cycles occur without a fault.
is “ON.” feed.

performed? System
Sensing Module with a DVM .
2. Disconnect the 3-pin connector at the ignition coil.
coil connector while cranking the engine connector.

13 Replace the PCM.
procedures.
D06RY00067
is “OFF.”
spark events.
is “ON.” feed.

performed? System
Sensing Module with a DVM positive lead with the
negative lead to ground.

13 Replace the PCM.
procedures.
D06RY00067
is “OFF.”
spark events.
is “ON.” feed.

performed? System

12 Repair the open in ignition control circuit.
13 Replace the PCM.
procedures.
D06RY00067
is “OFF.”
spark events.
When the PCM detects a problem on EST in control Conditions for Clearing the MIL/DTC
circuit 5, it will set a DTC P0355.
is “ON.” feed.

performed? System

13 Replace the PCM.
procedures.
D06RY00067
is “OFF.”
circuit monitoring.
is “ON.” feed.

performed? System

13 Replace the PCM.
procedures.
Diagnostic Trouble Code (DTC) P0401 EGR Flow Insufficient
D06RY00178
Circuit Description D TCC status is unchanged.

The powertrain control module (PCM) tests the exhaust
gas recirculation (EGR) system during deceleration by
Start Test
momentarily commanding the EGR valve to open while D TP angle is less than 1%.
monitoring the manifold absolute pressure (MAP) sensor D EGR duty cycle is less than 1%.
signal. When the EGR valve is opened, the PCM D MAP is steady, changing less than 2 kPa.
monitors the change in MAP input signal. The PCM D Engine speed is between 1100 RPM and 2000 RPM.
compares the MAP change to a RPM vs. BARO table. D MAP between 10 kPa and 40 kPa.
When the PCM interprets the change in MAP to be out of The test will be aborted if the vehicle speed changes by
limits, the PCM will set DTC P0401. The number of test more than 16 km/h (10 mph), engine speed changes by
samples required to accomplish this may vary according more than 100 RPM or the EGR is opened less than 95%
to the severity of the detected flow error. of commanded position.
Normally, the PCM will only allow one EGR flow test
D The PCM will only run the EGR test during a closed
sample to be taken during an ignition cycle. To aid in throttle condition.
verifying a repair, the PCM allows twelve test samples D The PCM will only run the EGR test at vehicle speeds
during the first ignition cycle following a Tech 2 “Clear Info” above 24 km/h (15 mph).
or a battery disconnect. Between nine and twelve D Several deceleration cycles will be necessary to run a
samples should be sufficient for the PCM to determine sufficient number of EGR flow tests.
adequate EGR flow and pass the EGR test.
Diagnostic Aids
D No TP sensor, vehicle speed sensor (VSS), MAP D Poor connection or damaged harness – Inspect the
sensor, EGR Pintle Position sensor, ECT sensor, wiring harness for damage. If the harness appears to
misfire, or automatic transmission DTCs set. be OK, observe the Actual EGR Position display on the
D Engine coolant temperature is greater than 60°C Tech 2 while moving connectors and wiring harnesses
(140°F). related to the EGR valve. A change in the display will
D Ignition voltage between 11.5 and 16 volts. indicate the location of the fault.
D Vehicle speed is greater than 24 km/h (15 mph). D Ensure EGR valve is correctly mounted. See
On-Vehicle Service.
D A/C clutch status is unchanged.
NOTE: If the EGR valve shows signs of excessive heat,
check the exhaust system for blockage (possibly a
plugged catalytic converter) using the “Restricted
Exhaust System Check.”
Test Description
Diagnostic Chart
3. A malfunctioning MAP sensor can set an EGR DTC.
The MAP sensor could send a constant signal which
is not low enough to set a low MAP DTC. The
constant signal from the MAP sensor also may not
be high enough to set a high MAP DTC. This step
verifies that the MAP sensor is responding.
DTC P0401 – EGR Flow Insufficient

performed? System
2 Is DTC P1404 also set? Go to DTC
— 1404 Go to Step 3
2. Monitor the MAP signal with a Tech 2 while idling.
3. While idling, jab the accelerator pedal about halfway
down and immediately let the engine return to idle.
Did the MAP value on the Tech 2 show an immediate
large change? — Go to Step 5 Go to Step 4
5 1. Inspect the exhaust system for modification of
original installed parts or leaks.
2. If a problem was found, repair exhaust system as
necessary.
Was a condition present that required repair? — Go to Step 8 Go to Step 6
6 1. Remove the EGR valve.
2. Visually and physically inspect the pintle, valve
passages and the adapter for excessive deposits or
any kind of a restriction.
3. If a problem is found, clean or replace EGR system
components as necessary.
Was a condition present that required repair? — Go to Step 8 Go to Step 7
7 1. Remove the EGR inlet and outlet pipes from the
exhaust manifold and the intake manifold.
2. Inspect the manifold EGR ports and the EGR inlet
and outlet pipes for a blockage caused by excessive
deposits or other damage.
3. If a problem is found, correct the condition as Refer to
necessary. Diagnostic
Was a condition present that required repair? — Go to Step 8 Aids
2. Clear DTC and monitor the Tech 2 System Info
Screen while operating the vehicle as specified in
“Diagnostic Aids.”
4. Note the test result.
Does the Tech 2 indicate DTC P0401 failed this Repair
ignition? — — complete
Diagnostic Trouble Code (DTC) P0402 EGR Pintle Crank Error
D06RY00178
Circuit Description D A history DTC P0402 will clear after 40 consecutive

The powertrain control module (PCM) monitors the EGR
valve pintle position input to ensure that the valve D DTC P0402 can be cleared by using the Tech 2 “Clear
responds properly to commands from the PCM, and to feed.
detect a fault if pintle position is stuck open. If the PCM
detects a pintle position signal indicates more than 21.5% Diagnostic Aids
and more than for 625 msec during cranking, the PCM will
set DTC P0402.
D Foreign material on EGR valve between pintle and
Conditions for Setting the DTC seat may cause EGR stuck open. Inspect foreign
material in EGR valve.
D Ignition voltage is between 11 and 16 volts. D Excessive carbon deposit may cause unsmooth
D Intake Air temp is more than 3°C operation of EGR valve shaft. Inspect carbon deposit
D At Engine revolution less than 600 RPM, EGR pintle and clean up inside of carbon deposit.
position indicates more than 21.0% and more than for D Poor connection or damaged harness–inspect the
625 msecs. wiring harness for damage If the harness appears to be
OK, observe the EGR actual position display on the
Action Taken When the DTC Sets Tech 2 while moving connectors and wiring harnesses
related to EGR valve. A change in the display will
D The PCM will illuminate the malfunction indicator lamp indicate the location of the fault.
fault is detected. NOTE: If the EGR valve shows signs of excessive heat,
D The PCM will store conditions which were present check the exhaust system for blockage (possibly a
when the DTC was set as Freeze Frame and in Failure plugged catalytic converter) using the “Restricted
Records data. Exhaust System Check”.

DTC P0402 – EGR Pintle Crank Open Error

performed? System
2 1. Ignition “ON”, engine “OFF”, review and record
Tech 2 Failure Records data.
until the DTC P0402 test runs. Note the result. Refer to
Does the Tech 2 indicates DTC P0402 failed this Diagnostic
3 1. Disconnect the EGR valve harness connector.
2. Inspect the EGR valve and connectors for damaged
pin or terminals.
Were there any damaged pins or terminals? — Go to Step 4 Go to Step 5
5 1. Remove EGR valve from Engine.
2. Inspect EGR valve whether there is any foreign
material between seat and pintle.
Was any foreign material in EGR valve? — Go to Step 6 Go to Step 7
6 1. Remove EGR valve foreign material from EGR
valve and clean up inside.
2. Visually inspect damage of pintle and seat, which
leakage may occur. Verify repair
Was there any severe damage which affects function? — Go to Step 7 Go to Step 8
7 1. Reconnect.
2. Ignition “OFF”.
4. Run the engine at idle.
5. On Tech-II, select special function for EGR.
6. Use the “UP” arrow to increase the EGR from 0% to
40%.
Did EGR work properly? — — Go to Step 8
8 Replace the EGR valve.
Does DTC P0402 still fail “DTC” test on the Tech 2? — Go to Step 9 Verify repair
Diagnostic Trouble Code (DTC) P0404 EGR Open Stuck
D06RY00178
when the DTC was set as Freeze Frame and in Failure
The powertrain control module (PCM) monitors the EGR Records data.
valve pintle position input to ensure that the valve
responds properly to commands from the PCM, and to Conditions for Clearing the MIL/DTC
detect a fault if pintle position is different from
commanded position. If the PCM detects a pintle position D The PCM will turn the MIL “OFF” on the third
signal indicates more than 15 points different between been run and the fault condition is no longer present.
current and commanded and more than 15 seconds, the
PCM will set DTC P0404. warm-up cycles have occurred without a fault.
D The engine is running. feed.
D Ignition voltage is between 11 and 16 volts.
D Intake Air temp is more than 3°C. Diagnostic Aids
D Desire EGR position is more than 0. Check for the following conditions:
D The difference between desired EGR and current EGR D Excessive carbon deposit on EGR valve shaft may
is less than 3%. cause EGR stuck open or unsmooth operation. Those
carbon deposit may occur by unusual port operation.
D Difference EGR pintle position between current and Clean up carbon may make smooth function of EGR
commanded position becomes more than 15% and valve.
last more than 15 seconds, and this condition meets
three times in a trip. Then it trigger, the PCM lights on. D Poor connection or damaged harness – Inspect the
wiring harness for damage. If the harness appears to
Action Taken When the DTC Sets be OK, observe the EGR actual position display on the
Tech 2 while moving connectors and wiring harnesses
D The PCM will illuminate the malfunction indicator lamp related to EGR valve. A change in the display will
(MIL) as soon as failure detected after consecutive 2nd indicate the location of the fault.
trip in which the fault is detected.
DTC P0404 – EGR Open Stuck

performed? System
2 1. Ignition “ON,” engine “OFF”, review and record
Tech 2 Failure Records Data.
pin or terminals.
Is the action
— Verify repair complete?
2. Inspect EGR valve whether there is any excessive
carbon deposit on EGR shaft.
Was excessive carbon deposit on EGR valve shaft? — Go to Step 6 Go to Step 7
6 1. Clean up EGR valve shaft and inside of EGR valve.
2. Visually inspect damage of pintle and seat if is bent,
leakage may occur. Verify repair
7 1. Reconnect.
5. On the Tech 2, select EGR Control Test.
40%.
9 Replace the PCM.
procedures.
Diagnostic Trouble Code (DTC) P0405 EGR Low Voltage
D06RY00178

The powertrain control module (PCM) monitors the EGR D The PCM will turn the MIL “OFF” on the third
valve pintle position input to ensure that the valve consecutive trip cycle during which the diagnostic has
responds properly to command from the PCM. If current been run and the fault condition is no longer present.
pintle position voltage indicates less than 0.1 V and last D A history DTC P0402 will clear after 40 consecutive
more than 10 seconds, then the PCM will set DTC P0405. warm-up cycles have occurred without a fault.
feed.
D EGR pintle position is less than 2% and last more than Diagnostic Aids
10 sec. Action taken when the DTC sets.
Action Taken When the DTC Sets D Poor connection or damaged harness – Inspect the
D The PCM will illuminate the malfunction indicator lamp be OK, observe the EGR actual position display on the
(MIL) as soon as failure detected. Tech 2 while moving connectors and wiring harnesses
D The PCM will store conditions which were present related to EGR valve. A change in the display will
when the DTC was set as Freeze Frame and in Failure indicate the location of the fault.
Records data.
DTC P0405 – EGR Low Volt

performed? System
pin or terminals.
5 1. Disconnect the EGR harness connector.
2. Ignition “ON”.
3. At the EGR valve, use a DVM to check the voltage
at the 5 volt reference wire (RED/YEL) and ground.
Did the DVM indicate the specified value? 4–6 V Go to Step 6 Go to Step 7
2. Measure resistance between terminal 5 Volt
reference wire and ground.
Was resistance in range? 5–5.5 KW Go to Step 10 Go to Step 17
7 1. Ignition “ON”.
2. At the PCM connector, back prove with a DVM at
the 5 volt reference for the EGR valve.
8 Repair the open 5 volt reference circuit.
9 Repair the damaged sensor ground wire.
10 1. Disconnect the EGR harness
2. Use an ohmmeter to measure between the pintle
position pin and the sensor ground pin on the EGR
valve.
NOTE: J-35616 Connector Test Adapter Kit may be
useful for gaining access to the recessed pins on the
valve.
Was the ohmmeter reading approximately equal to the
specified value? 1 to 1.25 KW Go to Step 13 Go to Step 17
2. Backprobe with a DVM to measure voltage at EGR
valve pintle position pin and sensor ground pin. Less than
Was voltage in range? 0.1 V Go to Step 17 Go to Step 12
DTC P0405 – EGR Low Volt (Cont'd)

2. Backprobe with a DVM to measure voltage at PCM
sensor ground pin and pintle position pin. Less than
Was voltage in range? 0.1 V Go to Step 13 Go to Step 18
2. Disconnect the EGR harness.
3. Check short circuit between EGR pintle position
circuit and EGR ground circuit.
Was any short circuit? — Go to Step 14 Go to Step 18
14 Locate and repair the short to ground in the pintle
position circuit
4. Measure the voltage between the EGR pintle
position circuit and ground. Less than
Is the measured voltage near the specified value? 0.1 V Go to Step 17 Go to Step 16
16 Check for a short circuit between other wires and the
pintle position circuit Repair short
Is there any short circuit? circuit
— Verify repair Go to Step 17
Does DTC P1404 still fail “DTC test on the Tech 2? — Go to Step 18 Verify repair
18 Examine the PCM pin and terminal connection.
Was there a damaged terminal? — Go to Step 4 Go to Step 19
19 Replace the PCM.
procedures.
Diagnostic Trouble Code (DTC) P0406 EGR High Voltage
D06RY00178

responds properly to command from the PCM. If current been run and the fault condition is no longer present.
pintle position voltage indicates more than 4.8 V and last D A history DTC P0402 will clear after 40 consecutive
more than 10 seconds, then the PCM will set DTC P0406. warm-up cycles have occurred without a fault.
feed.
D EGR pintle position is more than 99% and last more Diagnostic Aids
than 10 sec.
Action Taken When the DTC Sets D Poor connection or damaged harness – Inspect the
D The PCM will illuminate the malfunction indicator lamp be OK, observe the EGR actual position display on the
(MIL) as soon as failure detected. Tech 2 while moving connectors and wiring harnesses
D The PCM will store conditions which were present related to EGR valve. A change in the display will
when the DTC was set as Freeze Frame and in Failure indicate the location of the fault.
Records data.
DTC P0406 – EGR High Voltage

performed? System
pin or terminals.
Is the action
Is the action complete? — Verify repair complete?
3. At the EGR valve, use a DVM to check the voltage
at the 5 volt reference wire (RED/YEL).
2. At the PCM connector, backprove with a DVM at the
5 volt reference for the EGR valve.
7 Repair the open 5 volt reference circuit
8 1. Ignition “OFF”
3. Use a DVM to check for an resistance between 5 V
reference and Sensor Ground at EGR sensor
terminals.
NOTE: J-35616 Connector Test Adapter Kit may be
useful for gaining access to the recessed pins on the
valve.
Was the measured resistance in range? 5 to 5 KW Go to Step 9 Go to Step 15
3. Use a DVM to check for an resistance between
Sensor Ground and Signal wire at EGR sensor
terminal.
Is there an open circuit? — Go to Step 15 Go to Step 10
2. Disconnect the EGR harness at PCM connector.
3. Use a DVM to check for shorted wire between S37
and F53.
Is there a shorted wire? — Go to Step 14 Go to Step 11
DTC P0406 – EGR High Voltage (Cont'd)

2. Use a DVM to backprove at terminal Connector of
EGR valve for voltage. more than
Was measured voltage more than 4.8 V? 4.8 V Go to Step 12 Go to Step 12
2. Stay the EGR harness connected.
3. Check voltage by backproving at PCM S37
terminal.
Was voltage more than 4.8 V? 4.8 V Go to Step 16 Go to Step 13
13 1. Locate short circuit at EGR harness between
RED/YEL to RED/YEL or GRN, YEL/RED to
BLK/YEL.
2. Replace EGR harness.
14 Replace EGR harness.
Does DTC P1404 still fail “DTC test on the Tech 2? — Go to Step 16 Verify repair
16 Replace the PCM.
procedures.
Diagnostic Trouble Code (DTC) P0420 TWC System Low Efficiency Bank 1
T321075

To control emissions of hydrocarbons (HC), carbon D The PCM will illuminate the malfunction indicator lamp
monoxide (CO), and oxides of nitrogen (NOx), a (MIL) the first time the fault is detected.
three-way catalyst (TWC) is used. The catalyst promotes D The PCM will store conditions which were present
a chemical reaction which oxidizes the HC and CO when the DTC was set as Freeze Frame and in the
present in the exhaust gas, converting them into Failure Records data.
harmless water vapor and carbon dioxide. The catalyst
also reduces NOx, converting it to nitrogen. The Conditions for Clearing the MIL/DTC
powertrain control module (PCM) has the ability to D The PCM will turn the MIL “OFF” on the third
monitor this process using the Bank 1 HO2S 1 and the consecutive trip cycle during which the diagnostic has
Bank 1 HO2S 2 heated oxygen sensors. The Bank 1 been run and the fault condition is no longer present.
HO2S 1 sensor produces an output signal which indicates D A history DTC P0420 will clear after 40 consecutive
the amount of oxygen present in the exhaust gas entering warm-up cycles have occurred without a fault.
the three-way catalytic converter. The Bank 1 HO2S 2 D DTC P0420 can be cleared by using the Tech 2 “Clear
sensor produces an output signal which indicates the Info” function or by disconnecting the PCM battery
oxygen storage capacity of the catalyst; this in turn feed.
indicates the catalyst’s ability to convert exhaust gases
efficiently. If the catalyst is operating efficiently, the Bank
Diagnostic Aids
1 HO2S 1 signal will be far more active than that produced Check for the following conditions:
by the Bank 1 HO2S 2 sensor. If the PCM detects a level D Poor connection at PCM – Inspect harness connectors
of Bank 1 HO2S 2 activity that indicates the catalyst is no for backed-out terminals, improper mating, broken
longer operating efficiently, DTC P0420 will be set. locks, improperly formed or damaged terminals, and
Conditions for Setting the DTC D Damaged harness – Inspect the wiring harness for
D No related DTCs. display on the Tech 2 while moving connectors and
D The engine is operating in “closed loop.” wiring harnesses related to the sensor. A change in the
D Engine air load is below 99%. display will indicate the location of the fault.
D Engine coolant temperature is between 70°C (158°F)
and 120°C (248°F). diagnostic test last failed may help determine how often
D Mass air flow is between 2.5 g/second and 10
g/second. may assist in diagnosing the condition.
The “TWC Monitor Test Counter” displayed on the Tech 2
D Engine speed is below 200 RPM.
may be used to monitor the progress of the TWC
D Catalyst temperature is above 35°C (662°F). diagnostic. To complete the TWC diagnostic with a good
D The PCM determines that the catalyst’s oxygen catalyst, the counter must be allowed to increment to 49
storage capacity is below the acceptable threshold. samples and roll over to 0 at least twice. A failed catalyst
D Intake Air temperature is between –10°C (14°F) and will require three or more 50-sample tests to report a
70°C (158°F).
failure.
Test Description
Diagnostic Chart.
7. Difficulty completing the DTC P0420 “Status This
Ign.” test may be encountered in areas where test
conditions cannot be maintained easily, especially in
urban areas. To minimize the amount of driving
required to complete the DTC P0420 “Status This
Ign.” test, use the following procedure:
D Allow the engine to warm completely.
D With the vehicle in “Park,” monitor mass air flow on
the Tech 2 and hold part throttle to maintain a
reading of over 12 g/second for at least 2 minutes.
This will achieve the “warm catalyst” required for
running the test.
D Operate the vehicle in second or third gear to remain
in the DTC P0420 test conditions described in
“Conditions for Setting the DTC” as much as
possible. If you must stop the vehicle, maintain the
“warm catalyst” criteria as follows:
– Place the vehicle in “Park” or “Neutral.”
– Hold part throttle to maintain a mass air flow
reading of over 15 g/second for the duration of the
stop.
DTC P0420 – TWC System Low Efficiency Bank 1

performed? System
2 Are any other DTCs set (such as P0140)? Diagnose
other DTC(s)
— first Go to Step 3
3 1. Visually and physically inspect the three-way
catalytic converter for damage. Check for the
following:
D dents
D severe discoloration caused by excessive
temperatures
D holes
D internal rattle caused by damaged catalyst
2. Also, ensure that the three-way catalytic converter
is a proper original equipment manufacturer part.
Did your inspection reveal a problem? — Go to Step 6 Go to Step 4
4 1. Visually and physically inspect the exhaust system
between the three-way catalytic converter and the
rear converter flange for leaks, damage, and loose
or missing hardware.
Go to Step 7
2. If a problem is found, repair as necessary. to verify
Did your inspection reveal a problem? — repair Go to Step 5
5 1. Visually and physically inspect the Bank 1 HO2S 2.
2. Ensure that the Bank 1 HO2S 2 is secure and that
the pigtail and wiring harness is not contacting the
exhaust pipe or is not otherwise damaged.
Go to Step 7
6 Replace the three-way catalytic converter.
NOTE: Check for conditions which may cause catalyst
damage (refer to Diagnostic Aids). Go to Step 7
to verify
Is the action complete? — repair —
2. Clear DTC P0420.
3. Start the engine and allow it to warm up until the
engine coolant temperature monitored on the Tech
2 is above the specified value.
4. Run the engine to maintain the specified mass air
flow range for at least 2 minutes.
Engine
5. Operate the vehicle to maintain DTC P0420 test
conditions (refer to DTC Test Description in coolant temp:
Diagnostic Support for detailed instructions). greater than
60°C Repair
(140°F). complete. If
Mass air flow: a driveability
7. Note the test result. between 8 symptom still Go to the
Does the Tech 2 indicate DTC P0420 passed this g/second and exists, refer Diagnostic
ignition? 50 g/second to Symptoms. Aids
Diagnostic Trouble Code (DTC) P0430 TWC System Low Efficiency Bank 2
T321075
Circuit Description D Mass air flow is between 2.5 g/second and 10

g/second.
To control emissions of hydrocarbons (HC), carbon
monoxide (CO), and oxides of nitrogen (NOx), a D Change in engine load is below 8%.
three-way catalyst (TWC) is used. The catalyst promotes D Engine speed is below 200 RPM.
a chemical reaction which oxidizes the HC and CO D Catalyst temperature is above 350°C (662°F).
present in the exhaust gas, converting them into D The PCM determines that the catalyst’s oxygen
harmless water vapor and carbon dioxide. The catalyst storage capacity is below the acceptable threshold.
also reduces NOx, converting it to nitrogen. The D Intake Air temperature is between –20°C (4°F) and
powertrain control module (PCM) has the ability to 70°C (158°F).
monitor this process using the Bank 2 HO2S 1 and the
Bank 2 HO2S 2 heated oxygen sensors. The Bank 2 Action Taken When the DTC Sets
HO2S 1 sensor produces an output signal which indicates D The PCM will illuminate the malfunction indicator lamp
the amount of oxygen present in the exhaust gas entering (MIL) the first time the fault is detected.
the three-way catalytic converter. The Bank 2 HO2S 2 D The PCM will store conditions which were present
sensor produces an output signal which indicates the when the DTC was set as Freeze Frame and in the
oxygen storage capacity of the catalyst; this in turn Failure Records data.
indicates the catalyst’s ability to convert exhaust gases
efficiently. If the catalyst is operating efficiently, the Bank Conditions for Clearing the MIL/DTC
2 HO2S 1 signal will be far more active than that produced D The PCM will turn the MIL “OFF” on the third
by the Bank 2 HO2S 2 sensor. If the PCM detects a level consecutive trip cycle during which the diagnostic has
of Bank 2 HO2S 2 activity that indicates the catalyst is no been run and the fault condition is no longer present.
longer operating efficiently, DTC P0430 will be set. D A history DTC P0430 will clear after 40 consecutive
D No related DTCs. feed.
D The engine is operating in “closed loop.”
D Engine air load is below 99%.
D Engine coolant temperature is between 70°C (158°F)
and 115°C (239°F).
Diagnostic Aids
display on the Tech 2 while moving connectors and
wiring harnesses related to the sensor. A change in the
Test Description
Diagnostic Chart.
7. Difficulty completing the DTC P0430 “Status This
Ign.” test may be encountered in areas where test
conditions cannot be maintained easily, especially in
urban areas. To minimize the amount of driving
required to complete the DTC P0430 “Status This
Ign.” test, use the following procedure:
D Allow the engine to warm completely.
D With the vehicle in “Park,” monitor mass air flow on
the Tech 2 and hold part throttle to maintain a
reading of over 12 g/second for at least 2 minutes.
This will achieve the “warm catalyst” required for
running the test.
D Operate the vehicle in second or third gear to remain
in the DTC P0430 test conditions described in
“Conditions for Setting the DTC” as much as
possible. If you must stop the vehicle, maintain the
“warm catalyst” criteria as follows:
– Place the vehicle in “Park” or “Neutral.”
– Hold part throttle to maintain a mass air flow
reading of over 15 g/second for the duration of the
stop.
The “TWC Monitor Test Counter” displayed on the Tech 2
may be used to monitor the progress of the TWC
diagnostic. To complete the TWC diagnostic with a good
catalyst, the counter must be allowed to increment to 49
samples and roll over to 0 at least twice.
DTC P0430 – TWC System Low Efficiency Bank 2

performed? System
2 Are any other DTCs set (such as P0160)? Diagnose
other DTC(s)
3 1. Visually and physically inspect the three-way
catalytic converter for damage. Check for the
following:
D dents
D severe discoloration caused by excessive
temperatures
D holes
D internal rattle caused by damaged catalyst
2. Also, ensure that the three-way catalytic converter
is a proper original equipment manufacturer part.
Did your inspection reveal a problem? — Go to Step 6 Go to Step 4
4 1. Visually and physically inspect the exhaust system
between the three-way catalytic converter and the
rear converter flange for leaks, damage, and loose
or missing hardware.
Go to Step 7
5 1. Visually and physically inspect the Bank 2 HO2S 2.
2. Ensure that the Bank 2 HO2S 2 is secure and that
the pigtail and wiring harness is not contacting the
exhaust pipe or is not otherwise damaged.
Go to Step 7
6 Replace the three-way catalytic converter.
NOTE: Check for conditions which may cause catalyst
damage (refer to Diagnostic Aids). Go to Step 7
to verify
Is the action complete? — repair —
2. Clear DTC P0430.
3. Start the engine and allow it to warm up until the
engine coolant temperature monitored on the Tech
2 is above the specified value.
4. Run the engine to maintain the specified mass air
flow range for at least 6 minutes.
Engine
5. Operate the vehicle to maintain DTC P0430 test
conditions (refer to DTC Test Description in coolant temp:
Diagnostic Support for detailed instructions). greater than
70°C Repair
(158°F). complete. If
Mass air flow: a driveability
7. Note the test result. between 2.5 symptom still Go to the
Does the Tech 2 indicate DTC P0430 passed this g/second and exists, refer Diagnostic
ignition? 10 g/second to Symptoms. Aids
Diagnostic Trouble Code (DTC) P0440 EVAP System
D06RY00128
Circuit Description D Disconnected, damaged, pinched, or blocked fuel tank

vapor line
The evaporative system includes the following
components: D Disconnected or faulty EVAP canister cut valve
D Fuel tank D Disconnected or faulty EVAP canister duty solenoid
valve
D EVAP canister duty solenoid valve
D Open ignition feed circuit to the EVAP canister vent
D Fuel tank pressure sensor solenoid or the EVAP canister cut valve
D Fuel pipes and hoses D Damaged EVAP canister
D Vapor lines D Leaking fuel sender assembly O-ring
D Fuel cap D Leaking fuel tank or fuel filler neck
D Evaporative emissions canister Any of the above conditions can set DTC P0440.
D Purge lines
D EVAP canister cut valve (purge solenoid) Conditions for Setting the DTC
The evaporative leak detection diagnostic strategy is D No TP sensor, IAT sensor, or MAP sensor DTCs set.
based on applying vacuum to the EVAP system and D Start-up engine coolant temperature is less than 32°C
monitoring vacuum decay. The powertrain control (90°F).
module (PCM) monitors vacuum level via the fuel tank D Start-up engine coolant temperature is not more than
pressure sensor input. At an appropriate time, the EVAP 7°C (13°F) greater than start-up intake air
canister purge solenoid and the EVAP canister vent temperature.
solenoid are turned “ON,” allowing engine vacuum to D Start-up intake air temperature is greater than 4°C
draw a small vacuum on the entire evaporative emissions (39°F) .
system. If a sufficient vacuum level cannot be achieved, a D Start-up intake air temperature is not more than 2°C
large leak or a faulty EVAP canister purge solenoid is (4°F) greater than start-up engine coolant
indicated. This can be caused by the following conditions: temperature.
D Disconnected or faulty fuel tank pressure sensor D Vehicle speed is less than 5 mph (8 km/h).
D Missing or faulty fuel cap D Throttle position is greater than 3%.
D Disconnected, damaged, pinched, or blocked EVAP D Minimal fuel slosh.
purge line D BARO is greater than 70 kPa.
D Disconnected or damaged EVAP vent hose
D The EVAP system is unable to achieve or maintain D Kinked, pinched, or plugged vacuum source, EVAP
vacuum during the diagnostic test. purge, or fuel tank vapor line–Verify that the lines are
D Above conditions are present for 60 to 180 seconds. not restricted.
Action Taken When the DTC Sets diagnostic test last failed may help determine how often
D The PCM will illuminate the MIL during the second key
cycle in which the DTC sets. may assist in diagnosing the condition.
D The PCM will store conditions which were present Test Description
when the DTC set as Freeze Frame and in the Failure
Records data. Number(s) below refer to the step number(s) on the
Diagnostic Chart.
Conditions for Clearing the MIL/DTC 2. If an EVAP canister vent solenoid or an EVAP
D The PCM will turn the MIL “OFF” when the diagnostic canister purge solenoid electrical fault is present,
has been run and the fault condition is no longer the purge system will not operate correctly.
present. Repairing the electrical fault will very likely correct
D A history DTC P0440 will clear after 40 consecutive the condition that set DTC P0440.
warm-up cycles have occurred without a fault. 3. Checks the fuel tank pressure sensor at ambient
D DTC P0440 can be cleared by using the Tech 2 “Clear pressure.
feed. 4. Determines whether or not the EVAP system can be
sealed sufficiently to be pressurized. If not, the
Diagnostic Aids large leak must be located and corrected before
continuing with diagnosis.
5. Verifies that the fuel tank pressure sensor accurately
D Cracked or punctured EVAP canister.
reacts to EVAP system pressure changes.
D Damaged or disconnected source vacuum line, EVAP
purge line, vent hose or fuel tank vapor line. 8. Checks for a blocked EVAP canister purge solenoid.
D Poor connection at PCM – Inspect harness connectors The PCM commands the EVAP canister purge
for backed-out terminals, improper mating, broken solenoid “OFF” (open) and the vent solenoid “ON”
locks, improperly formed or damaged terminals, and (closed) with the Tech 2 “System Perf.” EVAP
poor terminal to wire connection. output control function activated. Any pressure in
D Damaged harness–Inspect the wiring harness to the the system should be released through the EVAP
EVAP canister vent solenoid, EVAP canister purge canister purge solenoid within a few seconds when
solenoid and the fuel tank pressure sensor for an “System Perf.” is activated.
intermittent open or short circuit. 9. Ensures that sufficient source vacuum is present at
the EVAP canister purge solenoid.
DTC P0440 – EVAP System

performed? System
2 Is DTC P0452 or P0453 also set? Go to other
— DTC first Go to Step 3
2. Remove the fuel cap.
4. Observe “Fuel Tank Pressure” on the Tech 2. Go to DTC
Does the Tech 2 indicate “Fuel Tank Pressure” at the P0452 or
specified value? 1.51 V Go to Step 4 DTC P0453
4 1. Replace the fuel cap.
2. Engine is running.
3. Observe “Fuel Tank Vacuum” on the Tech 2.
Does Tech 2 indicate “Fuel Tank Vacuum” at the
specified value? 1.47–1.51 V Go to Step 7 Go to Step 6
DTC P0440 – EVAP System (Cont'd)

2. Disconnect the fuel tank vapor line and the EVAP
purge line from the EVAP canister.
3. Block the canister fitting for the fuel tank vapor line.
4. Connect a hand vacuum pump to the canister fitting
for the EVAP purge line.
5. Ensure that the EVAP canister vent solenoid is still
commanded “ON” (closed).
6. Attempt to apply vacuum to the EVAP canister.
Observe “Fuel tank pressure” on the Tech 2.
Does the Tech 2 indicate “Fuel tank pressure” at the
specified value? 1.47–1.51 V Go to Step 8 Go to Step 7
6 1. Visually/physically check for the following
conditions:
D Restricted fuel tank vapor line.
D Restricted EVAP purge line.
Go to DTC
2. If a problem is found, repair as necessary. P0452 or
Was a problem found? — Verify repair DTC P0453
conditions:
D Vent hose disconnected or the damaged.
D EVAP canister damaged.
conditions:
D Missing or faulty fuel cap.
D Disconnected or leaking fuel tank vapor line.
D Disconnected or damaged EVAP purge line.
9 Replace the EVAP canister purge solenoid.
10 Locate and repair cause of no source vacuum to the
EVAP canister purge solenoid.
11 Replace the EVAP canister vent solenoid.
Diagnostic Trouble Code (DTC) P0442 EVAP System Small Leak Detected
D06RY00128

The evaporative system includes the following D No TP sensor, ECT sensor, Tank pressure sensor, IAT
components: sensor, or MAP sensor DTCs set.
D Fuel tank D The DTC P0440 diagnostic test has passed.
D EVAP canister vent solenoid D A vacuum decay condition, indicating a small leak, is
D Fuel tank pressure sensor detected during the diagnostic test.
D Fuel pipes and hoses
D Vapor lines
D Fuel cap D The PCM will illuminate the malfunction indicator lamp
(MIL) during the second key cycle in which the DTC
D Evaporative emissions canister sets.
D Purge lines D The PCM will store conditions which were present
D EVAP canister purge solenoid when the DTC was set as Freeze Frame and in the
The evaporative leak detection diagnostic strategy is Failure Records data.
based on applying vacuum to the EVAP system and
monitoring vacuum decay. The powertrain control Conditions for Clearing the MIL/DTC
module (PCM) monitors vacuum level via the fuel tank D The PCM will turn the MIL “OFF” on the third
pressure sensor input. At an appropriate time, the EVAP consecutive trip cycle during which the diagnostic has
canister purge solenoid and the EVAP canister vent been run and the fault condition is no longer present.
solenoid are turned “ON,” allowing engine vacuum to D A history DTC P0442 will clear after 40 consecutive
draw a small vacuum on the entire evaporative emissions warm-up cycles have occurred without a fault.
system. After the desired vacuum level has been D DTC P0442 can be cleared by using the Tech 2 “Clear
achieved, the EVAP canister purge solenoid is turned Info” function or by disconnecting the PCM battery
“OFF,” sealing the system. A leak is detected by feed.
monitoring for a decrease in vacuum level over a given
time period, all other variables remaining constant. A
Diagnostic Aids
small leak in the system will cause DTC P0442 to be set. Check for the following conditions:
D Cracked or punctured EVAP canister.
D Damaged source vacuum line, EVAP purge line, EVAP
vent hose or fuel tank vapor line.
D Poor connection at PCM – Inspect harness connectors Test Description
locks, improperly formed or damaged terminals, and Number(s) below refer to the step number(s) on the
poor terminal to wire connection. Diagnostic Chart.
D Damaged harness–Inspect the wiring harness to the 2. If an EVAP canister vent solenoid or an EVAP
EVAP canister vent solenoid, EVAP canister purge canister purge solenoid electrical fault is present,
solenoid and the fuel tank pressure sensor for an the purge system will not operate correctly.
intermittent open or short circuit. Repairing the electrical fault will very likely correct
Reviewing the Failure Records vehicle mileage since the the condition that set DTC P0442.
diagnostic test last failed may help determine how often 3. Checks the fuel tank pressure sensor at ambient
the condition that caused the DTC to be set occurs. This pressure.
4. Verifies that the fuel tank pressure sensor accurately
reacts to EVAP system pressure changes.
DTC P0442 – EVAP System Leak Detected

performed? System
Go to Fuel
4. Observe “Fuel Tank Pressure” on the Tech 2. Tank
Does the Tech 2 indicate “Fuel Tank Pressure” at the Pressure
specified value? 1.51V Go to Step 3 System
3 IMPORTANT: Before continuing with diagnosis, zero
the EVAP pressure and vacuum gauges on EVAP
pressure/purge cart J 41413 (refer to tool operating
instructions).
1. Replace the fuel cap.
2. Capture Failure Records data for DTC P0442 and
clear DTCs.
3. Connect the EVAP pressure/purge cart J 41413 to
the EVAP service port.
4. Using the Tech 2, command the EVAP canister vent
solenoid “ON” (closed).
5. Using the EVAP pressure/purge cart J 41413,
pressurize the EVAP system to the specified value.
Go to Fuel
4 1. Ignition “ON,” engine idling.
pressurize the EVAP system to 15 in. H2O.
4. Switch the rotary switch on the cart to “HOLD” and
observe the EVAP pressure gauge. Refer to
Does the pressure decrease to less than the specified Diagnostic
value within 2 minutes? 1.47 – 1.51V Go to Step 5 Aids
DTC P0442 – EVAP System Leak Detected (Cont'd)

5 1. Disconnect the fuel tank vapor line and the EVAP
purge line from the EVAP canister.
2. Block the canister fitting for the fuel tank vapor line.
3. Connect a hand vacuum pump to the canister fitting
for the EVAP purge line.
4. Ensure that the EVAP canister vent solenoid is still
commanded “ON” (closed).
5. Attempt to apply vacuum to the EVAP canister.
Can the vacuum be maintained at the specific value? 1.46V Go to Step 8 Go to Step 6
conditions:
D Vent hose disconnected or damaged.
conditions:
D Missing or faulty fuel cap.
D Disconnected or damaged EVAP purge line.
9 1. Using Tech 2, command the EVAP canister vent
2. With the cart connected to the EVAP service port,
continuously attempt to pressurize the EVAP
system by leaving the cart control knob in the
pressurize position.
3. Using ultrasonic leak detector J 41416, locate and
repair leak in EVAP system. (It may be necessary to
partially lower the fuel tank to examine the
connections on top of the tank.)
10 1. Ignition “ON,” engine not running.
pressurize and monitor the EVAP system to 15 in.
H2O.
4. Switch the rotary switch on the cart to “HOLD” and
observe the EVAP pressure gauge.
Does the pressure decrease to less than the specified
value within 2 minutes? 2.14V Go to Step 2 Verify repair
Diagnostic Trouble Code (DTC) P0446 EVAP Canister Vent Blocked
D06RY00128

The evaporative system includes the following D No TP sensor, ECT sensor, Tank pressure sensor, IAT
components: sensor, or MAP sensor DTCs set.
D Fuel tank D Start-up engine coolant temperature is less than 32°C
D EVAP canister vent solenoid (90°F).
D Fuel tank pressure sensor D Start-up engine coolant temperature is not more than
7°C (13°F) greater than start-up intake air
D Fuel pipes and hoses temperature.
D Vapor lines D Vehicle speed is less than 75 mph (120 km/h).
D Fuel cap D Throttle position is greater than 7% but less than 30%.
D Evaporative emissions canister D Minimal fuel slosh.
D Purge lines D Fuel tank level is between 10% and 90%.
D EVAP canister purge solenoid D BARO is greater than 70 kPa.
An incorrect fuel tank pressure sensor signal is detected
by monitoring fuel tank pressure when the key is first Action Taken When the DTC Sets
turned “ON” during a cold start. If the fuel tank pressure
signal is out of range, DTC P0446 will set. A restricted or D The PCM will illuminate the MIL during the second key
cycle in which the DTC sets.
blocked EVAP vent path is detected by monitoring fuel
tank pressure during normal operation (EVAP canister D The PCM will store conditions which were present
when the DTC set as Freeze Frame and Failure
vent solenoid open, EVAP canister purge solenoid Records data.
normal). With the EVAP canister vent solenoid open,
vacuum level in the system should be very low unless the Conditions for Clearing the MIL/DTC
vent path is blocked. A blockage can be caused by the
following condition: D The PCM will turn the MIL “OFF” on the third
D Faulty EVAP canister vent solenoid (stuck closed). been run and the fault condition is no longer present.
D Plugged, kinked or pinched vent hose. D A history DTC P0446 will clear after 40 consecutive
D Shorted EVAP canister vent solenoid driver circuit. warm-up cycles have occurred without a fault.
D Plugged evaporative canister.
If any of these conditions are present, DTC P0446 will set.
D DTC P0446 can be cleared by using the Tech 2 “Clear the condition that caused the DTC to be set occurs. This
Info” function or by disconnecting the PCM battery may assist in diagnosing the condition.
feed.
Test Description
Diagnostic Aids Number(s) below refer to the step number(s) on the
Check for the following conditions: Diagnostic Chart.
D Poor connection at PCM – Inspect harness connectors 2. If a vent solenoid electrical fault is present, the purge
for backed-out terminals, improper mating, broken system will not operate correctly. Repairing the
poor terminal to wire connection. electrical fault will very likely correct the condition
that set DTC P0446.
D Damaged harness–Inspect the wiring harness to the
EVAP canister vent solenoid, EVAP canister purge 3. Checks the fuel tank pressure sensor at ambient
solenoid and the fuel tank pressure sensor for an pressure.
intermittent open or short circuit. 4. Verifies that the fuel tank pressure sensor accurately
D Kinked, pinched, or plugged vent hose–Verify that the reacts to EVAP system pressure changes.
vent hose between the EVAP canister and EVAP
canister vent solenoid is not restricted. 6. Checks for a blocked EVAP canister.
DTC P0446– EVAP Canister Vent Blocked

performed? System
2. Capture Failure Records data for DTC P0446 and
clear DTCs.
Go to Fuel
Does Tech 2 indicate “Fuel Tank Pressure” at the Pressure
3 IMPORTANT: Before continuing with diagnosis, zero
the EVAP pressure and vacuum gauges on the EVAP
pressure/purge cart J 41413 (refer to tool operating
instructions).
1. Replace the fuel cap.
2. Using the Tech 2, command the EVAP vent solenoid
“ON” (closed).
3. Connect the EVAP pressure/purge cart J 41413 to
the EVAP service port.
pressurize the EVAP system to the specified value.
Go to Fuel
Does Tech 2 indicate “Fuel Tank Pressure” at the Pressure
specified value? 1.52 – 1.69V Go to Step 4 System
4 1. Maintain the EVAP pressure at 5 in. at H2O.
2. Using Tech 2, command the EVAP vent solenoid
“OFF” (open) while observing the EVAP pressure
gauge on the cart J 41413. Refer to
Does the EVAP pressure return to the specified value Diagnostic
within 5 seconds? 0 in. H2O Aids Go to Step 5
DTC P0446– EVAP Canister Vent Blocked (Cont'd)

5 1. Disconnect the large vent hose (marked “AIR”) from
the EVAP canister.
2. Switch the rotary switch on the cart J 41413 to
“PURGE.”
3. Ignition “ON,” engine idling at normal operating
temperature.
4. Observe vacuum gauge for 5 seconds while holding
the engine speed at 2500 RPM.
Does the vacuum remain less than the specified value? 30 in. H2O Go to Step 6 Go to Step 8
6 1. Inspect the vent hose between the EVAP canister
and the EVAP canister vent solenoid for kinks,
pinched areas, or any other form of blockage.
8 Replace the EVAP canister.
9 1. Using Tech 2, command the EVAP canister vent
pressurize and monitor the EVAP system to 15 in.
H2O.
3. Switch the rotary switch on cart J 41413 to “HOLD.”
solenoid “OFF” (open) while observing the EVAP
pressure gauge on cart J 41413.
Does the EVAP pressure return to the specified value
within 5 seconds? 0 in. H2O Verify repair Go to Step 2

P0452 Fuel Tank Pressure Sensor (Vapor Pressure Sensor) Low Voltage
D06RY00178

The powertrain control module (PCM) monitors fuel tank
pressure sensor (Vapor pressure sensor) of the D DTC P0404 can be cleared by using the Tech 2 “Clear
Enhanced Evapo system. When the tank pressure output feed.
indicates low voltage, PCM will set DTC P0452.
Diagnostic Aids
D Tank sensor output is less than 0.2 volts for 12.5 sec. D Open circuit of 5 volt reference line – Inspect wiring
D 100 test failures within a 200 tests. harness from PCM to the sensor. The PCM turns
P0452, and P0107 at the same time.
Action Taken When the DTC Sets D Open circuit or short circuit to ground line – Inspect
D The PCM will illuminate the malfunction indicator lamp wiring harness from PCM to the sensor. The PCM turns
(MIL) as soon as failure detected. P0452 and P0107 at the same time.
D The PCM will store conditions which were present D Tank fuel pressure sensor malfunction may cause
when the DTC was set as Freeze Frame and in Failure P0452.
Records data. Reviewing the Failure Records vehicle mileage since the
Conditions for Clearing the MIL/DTC the condition that caused the DTC to be set occurs. This
D The PCM will turn the MIL “OFF” on the third may assist in diagnosing the condition.
DTC P0452 – Tank Pressure Sensor Low Voltage

performed? System
conditions as noted. P0452/P0107
3. Using a Tech 2, monitor “DTC” info for DTC P0452 turn on
until the DTC P0452 test runs. Note the result. Go to Step 3 Refer to
Does the Tech 2 indicates DTC P0452 or P0452/P0107 P0452 turns on Diagnostic
failed this ignition? — Go to Step 6 Aids
2. Disconnect connector at the PCM.
4. At the PCM connector, measure voltage with a DVM
at F54 and S37 terminals.
Was the voltage in range of voltage? 4–6 V Go to Step 4 Go to Step 10
2. Connect the PCM connector to the PCM.
For P0452 go
3. Backprobe with a DVM at fuel tank pressure sensor to Step 5 and
between 5 V reference terminal and sensor ground for P0107, go
terminal. to diagnosis
Was the voltage within range? 4–6 V section. Go to Step 5
5 1. Locate open wiring of 5 volt reference circuit from
the PCM to fuel tank pressure sensor.
2. Repair wiring harness.
6 1. Ignition “ON”
sensor output for the voltage. Less than
Was voltage within the range? 0.2 V Go to Step 7 Go to Step 10
7 At the sensor output terminal, backprobe with a DVM at
the sensor output
Less than
8 1. Locate open circuit or short circuit to ground line.
2. Repair the harness.
DTC P0452 – Tank Pressure Sensor Low Voltage (Cont'd)

10 Replace the PCM.
procedures.

P0453 Fuel Tank Pressure Sensor (Vapor Pressure Sensor) High Voltage
D06RY00178

The powertrain control module (PCM) monitors fuel tank
pressure sensor (Vapor pressure sensor) of the D Info function or by disconnecting the PCM battery feed.
Enhanced Evapo system. When the tank pressure output
Diagnostic Aids
indicates high voltage , PCM will set DTC P0453.
Conditions for Setting the DTC D Open circuit of sensor ground line – Inspect wiring
harness from PCM to the sensor. The PCM turns
D Tank sensor output is more than 4.9 volts for 12.5 sec. P0453, and P0108 at the same time.
D 100 test failures within a 200 tests. D Open circuit or short circuit to 5 volt reference line –
Inspect wiring harness from PCM to the sensor. The
Action Taken When the DTC Sets PCM turns P0453 and P0108 at the same time.
D The PCM will illuminate the malfunction indicator lamp D Tank fuel pressure sensor malfunction may cause
(MIL) as soon as failure detected. P0453.
D The PCM will store conditions which were present Reviewing the Failure Records vehicle mileage since the
when the DTC was set as Freeze Frame and in Failure diagnostic test last failed may help determine how often
Records data. the condition that caused the DTC to be set occurs. This
DTC P0453 – Fuel Tank Pressure Sensor High Voltage

performed? System
conditions as noted. P0453/P0108
3. Using a Tech 2, monitor “DTC” info for DTC P0453 turn on
until the DTC P0453 test runs. Note the result. Go to Step 3 Refer to
Does the Tech 2 indicates DTC P0452 or P0452/P0107 P0452 turns on Diagnostic
failed this ignition? — Go to Step 6 Aids
2. Disconnect connector at the PCM.
4. At the PCM connector, measure voltage with a
DVM at F54 and S37 terminals.
Was the voltage in range of voltage? 4–6 V Go to Step 4 Go to Step 10
2. Connect the PCM connector to the PCM.
3. Disconnect sensor harness at fuel pressure sensor. For P0453 go
Measure voltage with a DVM at the end of the tank to Step 6 and
pressure wiring between 5 V reference terminal and for P0108, go
sensor ground terminal. to diagnosis
Was the voltage within range? 4–6 V section. Go to Step 5
5 1. Locate open wiring of ground line from the PCM to
fuel tank pressure sensor.
2. Repair wiring harness.
sensor output for the voltage. More than
7 At the sensor output terminal, backprobe with a DVM at
the sensor output.
More than
Was the voltage within range? 4.9 V Go to Step 9 Go to Step 8
9 Replace the tank pressure sensor.
DTC P0453 – Fuel Tank Pressure Sensor High Voltage (Cont'd)

10 Replace the PCM.
procedures.
Diagnostic Trouble Code (DTC) P0456 EVAP Very Small Leak
D06RY00128
Circuit Description Conditions for setting the DTC

The evaporative system includes the following D No MAP DTC’s set.
components: D No TPS DTC’s set.
D Fuel tank D No IAT DTC’s set.
D EVAP canister vent solenoid D No ECT DTC’s set.
D Fuel tank pressure sensor D No tank pressure sensor DTC’s set.
D Vapor lines D Baro is more than 70KPa.
D Fuel cap D A vacuum decay condition, indicating a very small leak,
D Evaporative emissions canister is detected during the diagnostic test.
D Purge lines
D EVAP canister purge solenoid Action Taken When the DTC Sets
The evaporative leak detection diagnostic strategy D The PCM will illuminate the malfunction indicator lamp
is based on applying vacuum to the EVAP (MIL) after the second consecutive trip in which the
systemand monitoring vacuum decay. The fault is detected.
powertrain control module(PCM)monitors vacuum D The PCM will store condition which were present when
level via the fuel tank presuure sensor input .At an the DTC was set as Freeze Frame and in the Failure
appropriate time, the EVAP canister purge Records data.
solenoid and the EVAP canister vent solenoid are Warm up cycles have occurred without a fault.
turned “ON,” allowing engine vacuum to draw a
very small on the entire evaporative emissions Conditions for Clearing the MIL/DTC
system. After the desired vacuum level has been D The PCM will turn the MIL “OFF” on the third
achieved, the EVAP canister purge solenoid is consecutive trip cycle during which the diagnostic has
turned “OFF”, sealing the system. A leak is been run and the fault condition is no longer present.
detected by monitoring for a decrease in vacuum D A history DTC P0456 will clear after 40 cosecutive trip
level over a given time period, all other variables cycle during which the warm up cycles have occurred
remaining constant. without a fault.
A very small leak in the system will cause DTC D DTC P0456 can be cleared using the Tech 2 “Clear
P0456 to be set. Info” function or by disconnecting the PCM battery
feed.
Diagnostic Aids D Damaged hanrness-Inspect the wiring harness to the
EVAP canister purge solenoid and the fuel tank
Check for the following conditions: pressure sensor for an intermittent open or short
D Cracked or punctured EVAP canister. circuit.
D Damaged source vacuum line, EVAP purge line, EVAP Reviewing the Failure Records vehicle mileage
vent hose or fuel tank vapor line. to wire connection. since the diagnostic test last failed may help
D Poor connection at PCM–Inspect harness connectors determine how often the condition that caused the
for backed out terminals, improper mating, broken DTC to be set occurs.
poor terminal to wire connection. This may assist in diagnosing the condition.
Diagnostic Trouble Code(DTC)P0456 EVAP Very Small Leak

1 Was the “On-Board(OBD)System Check”performed? Go to OBD
System
Go toFuel
specified value? 1.51V Go toStep 3 System
conditions:
D Vent hose disconnected or darmaged.
D Fuel cap damaged
2. If a problem is found,repair as necessary.
4 1. Ignition “ON”, engine “OFF”.
2. Install the fuel cap.
5. Using theTech 2,monitor the “DTC” info for DTC Refer to
P0456. Diagnostic
Does the Tech 2 indicate DTC P0456? — Go to Step 5 Aids
5 1. Ignition “ON”, engine idling.
2. Observe “Fuel Tank Pressure” on the Tech 2. Refer to
Does the Tech 2 indicate “Fuel Tank Pressure” at the Diagnostic
specified value? — Aids Go to Step 5
6 1. Ignition “ON”, engine idling.
2. Using theTech 2, command the EVAP canister vent
solenoid “ON” (closed)
3. Observe “EVAP canister vent solenoid operation”.
second value?
Diagnostic Trouble Code(DTC)P0456 EVAP Very Small Leak (Cont'd)

conditions:
D Disconnected or damage EVAP purge line.
Refer to
2. If a problem is found,repair as necessary. Diagnostic
Diagnostic Trouble Code (DTC) P0462 Fuel Level Sensor Circuit–Low Voltage
060RY00163

The fuel level sensor is an important input to powertrain D The PCM will not turn the malfunction indicator lamp
control module (PCM) for the enhanced evaporative (MIL) “ON.”
system diagnostic. Fuel level information is needed for D The PCM will store conditions which were present
the PCM to know the volume of fuel in the tank. The fuel when the DTC was set as Failure Records only. This
level affects the rate of change in air pressure in the information will not be stored as Freeze Frame data.
evaporative system. Several of the enhanced
evaporative system diagnostic sub-tests are dependent Conditions for Clearing the DTC
upon correct fuel level information. The diagnostic will not D The PCM will turn the MIL “OFF” after three
run when the tank is greater than 85%, or less than 15% consecutive trips without a fault condition present. A
full. Fuel level DTCs should be diagnosed before other history DTC will be cleared if no fault conditions have
evaporative system DTCs because they can cause other been detected for 40 warm-up cycles (engine coolant
DTCs to be set. temperature has risen 4°C (40°F) from the start-up
ECT, and ECT exceeds 71°C (160°F) during that
The sending unit is a float in the fuel tank which moves a same ignition cycle).
wiper arm across a variable resistor. Low fuel level D DTC P0462 can be cleared by using the scan tool
causes high resistance in the sending unit, and this is “Clear Info” function or by disconnecting the PCM
recognized by the PCM because the circuit operates at a battery feed.
corresponding low voltage. When the circuit is
continuously open or has a high resistance connection, Diagnostic Aids
DTC P0462 is set. D Damaged harness–Inspect the wiring harness for
Conditions for Setting the DTC fuel level display on the scan tool while moving
D Fuel tank level “slosh test” is completed. connectors and wiring harnesses related to the sensor.
D Fuel tank level “main test” is completed. fault.
D Fuel tank level data is valid.
D Fuel tank level signal is less than a specified value.
D There are 100 test failures within a 200-test sample.
Test Description
Diagnostic Chart.
8. The following chart can be used to check the
sending unit:
DTC P0462– Fuel Level Sensor Circuit –Low Voltage

performed? System
2 1. Disconnected the fuel level sensor harness from its
connector at the fuel tank.
3. Using a DVM, measure the voltage between the
sensor harness positive and ground wires.
Is the voltage approximately equal to the specified
2. With a DVM, backprobe the PCM connector at the
terminal which supplies 5 volts to the fuel level
sensor.
2. Fuel level sensor disconnected from wiring
harness.
3. With a DVM, probe the 5-volt supply wire at the
sensor harness.
Is the voltage approximately equal to the value
measured in Step 4? — Go to Step 5 Go to Step 9
5 Check for open or high resistance connection in the
ground wire between the PCM and the fuel level
sensor.
6 Remove the fuel level sensor and check the following:
D Does the arm move freely?
D Are the wires open or intermittently open when
wiggled?
D Do the resistance values match the specification
chart?
7 Replace the fuel level sensor.
8 Replace the PCM.
procedures. And also refer to latest Service Bulletin.
9 Short to ground between the PCM connector and the
fuel level sensor.
Diagnostic Trouble Code (DTC) P0463 Fuel Level Sensor Circuit–High Voktage
060RY00163

The fuel level sensor is an important input to powertrain D The PCM will not turn the malfunction indicator lamp
control module (PCM) for the enhanced evaporative (MIL) “ON.”
system diagnostic. Fuel level information is needed for D The PCM will store conditions which were present
the PCM to know the volume of fuel in the tank. The fuel when the DTC set as Failure Records only. This
level affects the rate of change in air pressure in the information will not be stored as Freeze Frame data.
evaporative system. Several of the enhanced
evaporative system diagnostic sub-tests are dependent Conditions for Clearing the DTC
upon correct fuel level information. The diagnostic will not D The PCM will turn the MIL “OFF” after three
run when the tank is greater than 85% or less than 15%, consecutive trips without a fault condition present. A
full. Fuel level DTCs should be diagnosed before other history DTC will be cleared if no fault conditions have
evaporative system DTCs because they can cause other been detected for 40 warm-up cycles (engine coolant
DTCs to be set. temperature has risen 4°C (40°F) from the start-up
ECT, and ECT exceeds 71°C (160°F) during that
The sending unit is a float in the fuel tank which moves a same ignition cycle) or the scan tool clearing function
wiper arm across a variable resistor. High fuel level has been used.
causes low resistance in the sending unit. This is D DTC P0463 can be cleared by using the scan tool
recognized by the PCM because the circuit operates at a “Clear Info” function or by disconnecting the PCM
corresponding high voltage. When the circuit is battery feed.
continuously shorted to a voltage source greater than a
specified value, or when the 5 volt signal is shorted to Diagnostic Aids
ground, DTC P0463 is set. D Damaged harness–Inspect the wiring harness for
Conditions for Setting the DTC fuel level display on the scan tool while moving
D Fuel tank level “slosh test” is completed. connectors and wiring harnesses related to the sensor.
D Fuel tank level “main test” is completed. fault.
D Fuel tank level data is valid.
D Fuel tank level signal is greater than a specified value.
D There are 100 test failures within a 200-test sample.
Test Description 2. The ETC and MAP sensors share a ground at PCM
Number(s) below refer to the step number(s) on the terminal D9.
Diagnostic Chart. 9. Equates the resistance values at various float
positions to the following fuel gauge readings:
DTC P0463– Fuel Level Sensor Circuit –High Voltage

performed? System
2 1. Disconnected the fuel level sensor harness from its
connector at the fuel tank.
3. Using a DVM, measure the voltage between the
sensor harness positive and ground wires.
3 With the negative DVM lead connected to ground, use
the positive DVM lead to probe the sensor ground wire
with the harness still disconnected.
Does the DVM indicate a short to a voltage source? — Go to Step 4 Go to Step 5
4 Repair short to voltage between the sensor and the
PCM.
Is the repair complete? — Verify repair —
5 With the negative DVM lead connected to ground, use
the positive DVM lead to probe the sensor positive wire
with the harness still disconnected.
Does the DVM indicate a voltage greater than the
specified value? 5V Go to Step 4 Go to Step 6
6 Open circuit between the PCM connector and the fuel
level sensor? — Verify repair Go to Step 7
7 Replace the PCM.
procedures. And also refer to latest Service Bulletin.
8 Remove the fuel level sensor and check the following:
D Does the arm move freely?
D Are the wire leads shorted together?
D Do the resistance values match the specification
chart?
9 Replace the fuel level sensor.
Is the repair complete? — Verify repair —
Diagnostic Trouble Code (DTC) P0502 VSS Circuit Low Input
D06RY00070

The vehicle speed sensor has a magnet rotated by the D The PCM will turn the MIL “OFF” on the third
transmission output shaft. Attached to the sensor is a hall consecutive trip cycle during which the diagnostic has
effect circuit the interacts with the magnetic field treated been run and the fault condition is no longer present.
by the rotating magnet. A 12-volt operating supply for the D A history DTC P0502 will clear after 40 consecutive
speed sensor hall circuit is supplied from the meter fuse. warm-up cycles have occurred without a fault.
The VSS pulses to ground the 9-volt signal sent from the D DTC P0502 can be cleared by using the Tech 2 “Clear
powertrain control module (PCM) on the reference circuit. Info” function or by disconnecting the PCM battery
The PCM interprets vehicle speed by the number of feed.
pulses to ground per second on the reference circuit.
Test Description
Conditions for Setting the DTC Number(s) below refer to the step number(s) on the
D Engine is running. Diagnostic Chart.
D Engine speed is between 1800 RPM and 2500 RPM. 10. To avoid backprobing the VSS and possibly
damaging a seal or terminal, the VSS output can be
D Throttle angle is between 10% and 40%. tested at the point where the transmission harness
D Engine load is greater than 50 kPa. connects to the engine harness. Power and ground
D PCM detects no VSS signal for 12.5 seconds over a are applied by jumpers to the VSS through the
period of 15 seconds. connectors which are located to the rear of the air
cleaner assembly. The VSS signal is monitored
Action Taken When the DTC Sets with a DVM as the rear driveshaft turns. The
D The PCM will illuminate the malfunction indicator lamp wheels can be turned to rotate the driveshaft, or in
(MIL) the first time the fault is detected. 2-wheels-drive vehicles the driveshaft can be turned
D The PCM will store conditions which were present directly.
DTC P0502 – VSS Circuit Low Input

performed? System
2 Does the speedometer work? — Go to Step 10 Go to Step 3
3 1. Disconnect the VSS connector.
3. Using a test light to battery +, probe the connector
ground wire.
4 Repair the sensor ground.
5 1. Ignition “ON,” sensor disconnected.
2. Using a DVM, measure at the VSS connector
between ground and voltage supply. Battery
Was the measurement near the specified value? voltage Go to Step 7 Go to Step 6
6 Repair the open or short to ground which may have
blown the meter fuse.
7 1. Ignition “ON,” VSS disconnected.
2. Using a DVM, measure at the VSS connector
between ground and the wire from the
speedometer.
Was the measurement near the specified value? 7.5-8 V Go to Step 9 Go to Step 8
8 Check for an open or short circuit between the
speedometer and the VSS.
Was an open or short circuit located? — Verify repair Go to Step 9
9 Replace the speedometer.
DTC P0502 – VSS Circuit Low Input (Cont'd)

2. Disconnect the MAF sensor. The connector
attaches the VSS wires from the transmission
harness to the left-side engine harness.
3. Disconnect the black 16-way connector.
4. Select a terminal adapter from kit J 35616 that can
be used with a jumper to supply B+ to the blue wire
with a yellow tracer (transmission side of the
connector).
5. Use another terminal adapter to attach a voltmeter
to the light-green wire with a white tracer (next to the
wire in the previous step.)
6. Disconnect the blue connector next to the black
16-way connector, and locate the black/red tracer
wire at one corner of the blue connector. The
black/red wire is the VSS ground. Use a terminal
adapter to attach a jumper to ground to the
black/red VSS ground wire at the transmission side
of the blue connector.
7. Raise the rear wheels off the ground with
transmission in neutral.
Does the DVM toggle back and forth between 0.6 V and
10 V as the wheels (and driveshaft) are rotated? — Go to Step 11 Go to Step 10
11 Replace the VSS.
12 Check for an open or short between the PCM and the
speedometer.
13 Replace the PCM.
procedures.
ANd also refer to latest Service Bulletin.
Diagnostic Trouble Code (DTC) P0506 Idle Air Control System Low RPM
D06RY00158
Circuit Description D Engine speed is more than 100-200 RPM lower than
desired idle based upon coolant temperature.
The powertrain control module (PCM) controls engine
speed by adjusting the position of the throttle control Action Taken When the DTC Sets
valve (DC motor). The throttle motor is a DC motor driven
by one coil. The PCM applies current to the DC motor coil D The PCM will illuminate the malfunction indicator lamp
in position (%) to adjustment the throttle valve into a (MIL) after the second consecutive trip in which the
fault is detected.
passage in the throttle body to air flow. This method
allows highly accurate control of engine speed and quick D The PCM will store conditions which were present
response to changes in engine load. Failure Records data.
If the PCM detects a condition where too low of an idle
speed is present and the PCM is unable to adjust idle Conditions for Clearing the MIL/DTC
speed by increasing the throttle position, DTC P0506 will
set, indicating a problem with the idle control system. Info” function or by disconnecting the PCM battery
feed.
D No TPS, VSS, ECT, EGR, MAF, low voltage, fuel Diagnostic Aids
system, canister purge, injector control, or ignition Check for the following conditions:
control DTCs are set.
D Poor connection at PCM or throttle DC motor – Inspect
D MAP is less than 60 kPa. harness connectors for backed-out terminals,
D Canister purge duty cycle is above 10%. improper mating, broken locks, improperly formed or
D Engine running time is more than 125 seconds. damaged terminals, and poor terminal-to-wire
D Vehicle speed is less than 1 mph. connection.
D Engine coolant temperature (ECT) is above 50°C. D Damaged harness – Inspect the wiring harness for
damage.
D Ignition voltage is between 9.5 volts and 16.7 volts. D Restricted air intake system – Check for a possible
D The throttle is closed. collapsed air intake duct, restricted air filter element, or
D EVAP purge duty cycle more than 10%. foreign objects blocking the air intake system.
D All conditions are met for 10 seconds. D Throttle body – Check for objects blocking the ETC
passage or throttle bore, excessive deposits in the
ETC passage and on the ETC position, and excessive Reviewing the Failure Records vehicle mileage since the
deposits in the throttle bore and on the throttle plate. diagnostic test last failed may help determine how often
D Large vacuum leak – Check for a condition that causes the condition that caused the DTC to be set occurs. This
a large vacuum leak, such as an incorrectly installed or may assist in diagnosing the condition.
faulty PCV valve or brake booster hose disconnected.
DTC P0506 – Idle Air Control System Low RPM

1 Was the “On-Board (OBD) System Check” performed? Go toOBD
System
— Go toStep 2 Check
intake system.
deposits in the throttle passage and on the
throttle valve, and excessive deposits in the
throttle bore and on the throttle plate.
D Throttle body with lever: Check for objects send
Refer
round the throttle spring lever that lever is smooth
toappropriate
movement, and spring lever has not excessive
section
play
foron–vehicle
Do any of the above require a repair? — service Go toStep 4
D Acceleration pedaL : Check for objects blocking
D Acceleration pedal : Check for objects move the
Refer
acceleration pedal that pedal is smooth
toappropriate
section
excessive play.
foron–vehicle
Do any of the above require a repair? — service Go toStep 4
harness connector.
necessary.
Was a problem found? — Verify repair Go toStep 7
5 Check the following circuits for an open, short
tovoltage, short to ground, or poor connection at
thePCM:
D Throttle DC motor circuit. Vcc-GND
D Throttle DC motor resistance. SIG-DND
change
D If a problem is found, repair as necessary. resistance0.3
Was a problem found? – 100W Verify repair Go toStep 6
DTC P0506 – Idle Air Control System Low RPM (Cont'd)

Is the action complete? — Go toStep 3 —
7 1. Check the following circuits for an open, short
tovoltage, short to ground, or poor connection at the
PCM:
Acceleration position sensor 1 circuit.
Acceleration position sensor 2 circuit.
C position sensor 2 circuit. Vcc-GND
V position sensor resistance. 4–6kW
SIG-DND
2. If a problem is found, repair as necessary. change
Was a problem found? resistance Verify repair Go toStep 8
Is the action complete? — Go toStep 9 —
9 Following below the DTCs stored: P1125, P1290,
Go
P1295, P1299
toapplicableD
— TC table Go toStep 10
10 Following below the DTCs stored:P1514, P1515,
Go
P1516, P1523, P1271, P1272, P1273
toapplicable
— DTC table Go toStep 11
11 Replace the PCM.
procedures.
Diagnostic Trouble Code (DTC) P0507 Idle Air Control System High RPM
D06RY00158

The powertrain control module (PCM) controls engine D The PCM will illuminate the malfunction indicator lamp
speed by adjusting the position of the throttle control (MIL) after the second consecutive trip in which the
valve (DC motor). The throttle motor is a DC motor driven fault is detected.
by one coil. The PCM applies current to the DC motor coil D The PCM will store conditions which were present
in position (%) to adjustment the throttle valve into a when the DTC was set as Freeze Frame and in the
passage in the throttle body to air flow. This method Failure Records data.
allows highly accurate control of engine speed and quick
response to changes in engine load. Conditions for Clearing the MIL/DTC
If the PCM detects a condition where too high of an idle D The PCM will turn the MIL “OFF” on the third
speed is present and the PCM is unable to adjust idle consecutive trip cycle during which the diagnostic has
speed by increasing the throttle position, DTC P0507 will been run and the fault condition is no longer present.
set, indicating a problem with the idle control system. D A history DTC P0507 will clear after 40 consecutive
D No TPS, VSS, ECT, EGR, MAF, low voltage, fuel feed.
system, canister purge, injector control or ignition
control DTCs are set. Diagnostic Aids
D Barometric pressure is above 75 kPa.
D Canister purge duty cycle is above 10%.
D Poor connection at PCM or throttle DC motor – Inspect
D Engine running time is more than 125 seconds. harness connectors for backed-out terminals,
D Vehicle speed is less than 1 mph. improper mating, broken locks, improperly formed or
D Engine coolant temperature (ECT) is above 50°C. damaged terminals, and poor terminal-to-wire
D Ignition voltage is between 9.5 volts and 16.7 volts. connection.
D The throttle is closed. D Damaged harness – Inspect the wiring harness for
damage.
D EVAP purge duty cycle is more than 10%.
D Vacuum leak – Check for a condition that causes a
D All conditions are met for 10 seconds. vacuum leak, such as disconnected or damaged
D Engine speed is more than 100-200 RPM higher than hoses, leaks at EGR valve and EGR pipe to intake
desired idle based upon coolant temperature.
manifold, leak at the throttle body, a faulty or incorrectly If DTC P0507 cannot be duplicated, reviewing the Failure
installed PCV valve, leaks at the intake manifold, etc. Records vehicle mileage since the diagnostic test last
D Throttle body – Check for sticking throttle plate. Also failed may help determine how often the condition that
inspect the air passage for deposits or objects which caused the DTC to be set occurs. This may assist in
will not allow the ETC position to fully extend or diagnosing the condition.
properly seat.
DTC P0507 – Idle Air Control System High RPM

System
intake system.
Refer to
appropriate
section for
play
on-vehicle
Do any of the above require a repair? — service Go to Step 4
D Acceleration pedaL : Check for objects blocking
Refer to
appropriate
section for
excessive play.
on-vehicle
harness connector.
necessary.
PCM:
D Throttle DC motor circuit. Vcc-GND
D Throttle DC motor resistance. SIG-DND
change
D If a problem is found, repair as necessary. resistance 0.3
Was a problem found? – 100W Verify repair Go to Step 6
DTC P0507 – Idle Air Control System High RPM (Cont'd)

7 1. Check the following circuits for an open, short
tovoltage, short to ground, or poor connection at the
PCM:
D C position sensor 3 circuit. Vcc-GND
4–6kW
D V position sensor resistance.
SIG-DND
2. If a problem is found, repair as necessary. change
Was a problem found? resistance Verify repair Go to Step 8
9 Following below the DTCs stored: P1125, P1290,
Go to
P1295, P1299
applicable
10 Following below the DTCs stored:P1514, P1515,
Go to
P1516, P1523, P1271, P1272, P1273
applicable
11 Replace the PCM.
procedures.
Diagnostic Trouble Code (DTC) P0562 System Voltage Low
D06RY00073

The powertrain control module (PCM) monitors the D A history DTC P0562 will clear after 40 consecutive
system voltage on the ignition feed terminal to the PCM. warm-up cycles have occurred without a fault.
A system voltage DTC will set whenever the voltage is D DTC P0562 can be cleared by using the Tech 2 “Clear
below a calibrated value. Info” function or by disconnecting the PCM battery
feed.
Diagnostic Aids
D Ignition “ON.”
D System voltage is below 11.5 volts for 15 minutes. If the DTC sets when an accessory is operated, check for
a poor connection or excessive current draw.
D The PCM will not illuminate the malfunction indicator
lamp (MIL).
D The PCM will store as Failure Records conditions
which were present when the DTC was set. This
information will not be stored as Freeze Frame data.
DTC P0562 – System Voltage Low

performed? System
2 Using a DVM, measure the battery voltage at the
Charge
battery.
battery, then
Is the battery voltage greater than the specified value? 11.5 V Go to Step 3 go to Step 3
3 1. Install a Tech 2.
2. Select “Ignition Volts” on the Tech 2.
3. Start the engine and raise the engine speed to the
specified value.
4. Load the electrical system by turning on the
headlights, high blower, etc. Go to
Is the ignition voltage approximately equal to the 2000 RPM Starting/Char
specified value? 12.8-14.1 V Go to Step 4 ging
4 1. Ignition “OFF.” Check for
2. Disconnect the PCM connector at the PCM. excessive
current draw
3. Using a DVM, measure the battery voltage at the
with ignition
PCM connector F-20 and F-57.
“OFF,” engine
Is it approximately equal to battery voltage? — “OFF.” Go to Step 5
5 1. Check for faulty connections at the PCM harness
terminals.
2. Repair as necessary.
Was a repair necessary? — Verify repair Go to Step 6
6 Check for an open battery feed circuit to the PCM.
7 Replace the PCM.
procedures.
Diagnostic Trouble Code (DTC) P0563 System Voltage High
D06RY00073

The powertrain control module (PCM) monitors the D A history DTC P0563 will clear after 40 consecutive
system voltage on the ignition feed terminals to the PCM. warm-up cycles have occurred without a fault.
A system voltage DTC will set whenever the voltage is D DTC P0563 can be cleared by using the Tech 2 “Clear
above a calibrated value. Info” function or by disconnecting the PCM battery
feed.
Diagnostic Aids
D Ignition “ON.”
D System voltage is above 16 volts for 15 minutes. If the DTC sets when an accessory is operated, check for
a poor connection or excessive current draw.
lamp (MIL).
D The PCM will store as Failure Records only conditions
which were present when the DTC was set. This
DTC P0563 – System Voltage High

1 Was the “ON-Board Diagnostic (OBD) System Check” Go to OBD
performed? System
2 Using a DVM, measure the battery voltage at the
battery.
Is the battery voltage less than the specified value? 11.5 V Go to Step 3 Go to Step 4
3 1. Charge the battery and clean the battery terminals.
2. Clean the battery ground cable connection if
corrosion is indicated. Replace
Is the battery voltage less than the specified value? 11.5 V battery Go to Step 4
4 1. Turn “OFF” all the accessories.
3. Select the ignition voltage parameter on the Tech 2.
4. Start the engine and raise the engine RPM to the
specified value. Go to
Is the voltage more than 2.5 volts greater than the Starting/Char
measurement taken in step 2 or 3? 2000 RPM ging Go to Step 5
5 Replace the PCM.
procedures.
Diagnostic Trouble Code (DTC) P0601 PCM Memory
060RY014
when the DTC was set in the Failure Records data only.
The powertrain control module (PCM) used in this vehicle
utilizes an electrically erasable programmable read-only Conditions for Clearing the MIL/DTC
memory (EEPROM). The EEPROM contains program
information and the calibrations required for engine, D The PCM will turn the MIL “OFF” on the third
transmission, and powertrain diagnostics operation. consecutive trip cycle during which the diagnostic has
Unlike the PROM used in past applications, the EEPROM
is not replaceable. When the PCM is replaced or a D A history DTC P0601 will clear after 40 consecutive
calibration update is required, the PCM must be
programmed using a Tech 2. Refer to On-Vehicle Service D DTC P0601 can be cleared by using the Tech 2 “Clear
in Powertrain Control Module and Sensors for the feed.
EEPROM programming procedure.
Diagnostic Aids
D DTC P0601 indicates that the contents of the
D The PCM detects an internal program fault (check sum EEPROM have changed since the PCM was
error). programmed. The only possible repair is PCM
replacement. Remember to program the replacement
Action Taken When the DTC Sets PCM with the correct software and calibration for the
vehicle.
lamp (MIL).
DTC P0601 – PCM Memory

performed? System
2 Replace the PCM.
procedures.
Diagnostic Trouble Code (DTC) P0602 PCM Programming Error
060RY014
The powertrain control module (PCM) used Main CPU
and Watchdog CPU software/calibration. Conditions for Clearing the MIL/DTC
D This code detects inconsistencies between Main CPU been run and the fault condition is no longer present.
and Watchdog CPU software/calibration.
D The PCM will not illuminate the malfunction indicator Info” function or by disconnecting the PCM battery
lamp (MIL). feed.
DTC P0602 – PCM Programming Error

performed? System
2 Replace the PCM.
procedures.
Diagnostic Trouble Code (DTC) P0604 PCM RAM Error
060RY014
The powertrain control module (PCM) used Main CPU
RAM and Watchdog CPU RAM. Conditions for Clearing the MIL/DTC
D This code detects inconsistencies between Main CPU been run and the fault condition is no longer present.
RAM and Watchdog CPU RAM.
D The PCM will not illuminate the malfunction indicator Info” function or by disconnecting the PCM battery
lamp (MIL). feed.
DTC P0604 – PCM RAM Error

performed? System
2 Replace the PCM.
procedures.
Diagnostic Trouble Code (DTC) P0606 PCM Internal Performance
060RY014

The input/output devices in the PCM include D The PCM will not illuminate the malfunction indicator
analog-to-digital converters, signal buffers, counters, and lamp (MIL).
special drivers. The PCM controls most components with D The PCM will store conditions which were present
electronic switches which complete a ground circuit when when the DTC was set in the Failure Records data only.
turned “ON”. These switches are arranged in groups of 4
and 7, called either a surface-mounted quad driver Conditions for Clearing the MIL/DTC
module (QDM), which can independently control up to 4 D The PCM will turn the MIL “OFF” on the third
output terminals, or QDMs which can independently consecutive trip cycle during which the diagnostic has
control up to 7 outputs. been run and the fault condition is no longer present.
D This code detects inconsistencies between Main CPU D DTC P0606 can be cleared by using the Tech 2 “Clear
A/D converters and Watchdog CPU A/D converters. Info” function or by disconnecting the PCM battery
feed.
DTC P0606 – PCM Internal Performance

performed? System
2 Replace the PCM.
procedures.

P1106 MAP Sensor Circuit Intermittent High Voltage
D06RY00165

The manifold absolute pressure (MAP) sensor responds D The PCM will not illuminate the malfunction indicator
to changes in intake manifold pressure (vacuum). The lamp (MIL).
MAP sensor signal voltage to the PCM varies from below D The PCM will store conditions which were present
2 volts at idle (high vacuum) to above 4 volts with the when the DTC was set as Failure Records data only.
ignition “ON,” engine not running or at wide-open throttle This information will not be stored as Freeze Frame
(low vacuum). data.
changes while the liner EGR flow test diagnostic is being Conditions for Clearing the MIL/DTC
run (refer to DTC P0401), to determine engine vacuum D A history DTC P1106 will clear after 40 consecutive
level for some other diagnostics and to determine warm-up cycles have occurred without a fault.
barometric pressure (BARO). The PCM compares the D DTC P1106 can be cleared by using the Tech 2 “Clear
MAP sensor signal to a calculated MAP based on throttle Info” function or by disconnecting the PCM battery
position and various engine load factors. If the PCM feed.
detects a MAP signal that is intermittently above the
calculated value, DTC P1106 will set.
Diagnostic Aids
Conditions for Setting the DTC D Leaking or plugged vacuum supply line to the MAP
sensor.
D No TP sensor DTCs are present.
D Inspect PCM harness connectors for backed-out
D Engine is running for at least 10 seconds. terminals, improper mating, broken locks, improperly
D Throttle angle is below 3% if engine speed is below formed or damaged terminals, and poor
1000 RPM. terminal-to-wire connection.
D Throttle angle is below 10% if engine speed is above D Inspect the wiring harness for damage. If the harness
1000 RPM. appears to be OK, observe the MAP display on the
D The MAP sensor indicates an intermittent manifold Tech 2 while moving connectors and wiring harnesses
absolute pressure above 80 kPa for a total of related to the sensor. A change in the display will
approximately 5 seconds over a 16-second period of indicate the location of the fault.
time.
Reviewing the Failure Records vehicle mileage since the D The MAP sensor shares a ground with the Fuel Tank
diagnostic test last failed may help determine how often Pressure sensor and the ECT Sensor. Check the
the condition that caused the DTC to be set occurs. This ground if these other DTCs are also set.
D The MAP sensor shares a 5 Volt Reference with the
Fuel Tank Pressure sensor. Check the 5 Volt reference
if this DTC is also set.
DTC P1106 – MAP Sensor Circuit Intermittent High Voltage

performed? System
P0108 chart
3 Are DTC P1111, P1115, and/or P1120 also set? — Go to Step 6 Go to Step 4
4 Check for a poor sensor ground circuit terminal
connection at the MAP sensor.
5 Check the MAP signal circuit between the MAP sensor
connector and the PCM for an intermittent short to
voltage.
6 Check for an intermittent short to voltage on the 5 volt
reference circuit between the PCM and the following
components:
D MAP sensor
D EGR valve
D TP sensor
7 Check for a poor sensor ground circuit terminal
8 Check for an intermittent open or a faulty splice in the
Refer to
Diagnostic
Was a problem found? — Go to Step 10 Aids
9 Replace the faulty harness connector terminal for the
10 Locate and repair the intermittent open/short circuit in
the wiring harness as necessary.
Diagnostic Trouble Code (DTC) P1107 MAP Circuit Intermittent Low Voltage
D06RY00165

The manifold absolute pressure (MAP) sensor responds D The PCM will not illuminate the malfunction indicator
to changes in intake manifold pressure (vacuum). The lamp (MIL).
MAP sensor signal voltage to the powertrain control D The PCM will store conditions which were present
module (PCM) varies from below 2 volts at idle (high when the DTC was set as Failure Records data only.
vacuum) to above 4 volts with the ignition “ON,” engine This information will not be stored as Freeze Frame
not running or at wide-open throttle (low vacuum). data.
changes while the linear EGR flow test diagnostic is being Conditions for Clearing the MIL/DTC
run (refer to DTC P0401), to determine engine vacuum D A history DTC P1107 will Clear after 40 consecutive
level for some other diagnostics and to determine warm-up cycles have occurred without a fault.
barometric pressure (BARO). The PCM compares the D DTC P1107 can be cleared by using the Tech 2 “Clear
MAP sensor signal to a calculated MAP based on throttle Info” function or by disconnecting the PCM battery
position and various engine load factors. If the PCM feed.
detects a MAP signal that is intermittently below the
calculated value, DTC P1107 will be set.
Diagnostic Aids
Conditions for Setting the DTC D Poor connection at PCM – Inspect harness connectors
D No TP sensor DTCs are present. locks, improperly formed or damaged terminals, and
D Engine is running. poor terminal-to-wire connection.
D Ignition voltage is more than 11 volts. D The MAP Sensor shares a 5 Volt reference with the
D Throttle angle is above 1% if engine speed is less than EGR Valve. If these codes are also set, it could indicate
1000 RPM. a problem with the 5 Volt reference circuit or
D Throttle angle is above 2% if engine speed is above components itself.
1000 RPM. D The MAP Sensor share a ground with the EGR Valve
D The MAP sensor indicates an intermittent manifold and the IAT Sensor.
absolute pressure below 11 kPa for a total of D Damaged harness – Inspect the wiring harness for
approximately 5 seconds over a 16-second period of damage. If the harness appears to be OK, observe the
time. MAP display on the Tech 2 while moving connectors
and wiring harnesses related to the sensor. A change the condition that caused the DTC to be set occurs. This
in the display will indicate the location of the fault. may assist in diagnosing the condition.
DTC P1107 – MAP Sensor Circuit Intermittent Low Voltage

performed? System
P0107 chart
3 Check for a poor 5 volt reference circuit or MAP signal
circuit terminal connection at the MAP sensor.
4 Check the MAP signal circuit between the MAP sensor
connector and the PCM for an intermittent open or
short to ground.
5 Check for an intermittent short to ground on the 5 volt
reference circuit between the PCM and the following
components:
D MAP sensor
D EGR valve
D TP sensor
6 Check for a poor 5 volt reference terminal connection at
the PCM.
7 Check for an intermittent open or a faulty splice in the 5
volt reference circuit.
Was a problem found? (If no, start with the diagnosis Refer to
chart for other sensors in the circuit and see if 5V Diagnostic
returns.) — Go to Step 9 Aids
8 Replace the faulty harness connector terminal(s) for
the 5 volt reference circuit and/or the MAP signal circuit
as necessary.
9 Repair intermittent open/short circuit in the wiring
harness as necessary.

P1111 IAT Sensor Circuit Intermittent High Voltage
D06RY00168
when the DTC set as Failure Records data only. This
The intake air temperature (IAT) sensor is a thermistor information will not be stored as Freeze Frame data.
which measures the temperature of the air entering the
D DTC P1111 does not illuminate the MIL.
engine. The powertrain control module (PCM) applies 5
volts through a pull-up resistor to the IAT sensor. When Conditions for Clearing the MIL/DTC
the intake air is cold, the sensor resistance is high and the
PCM will monitor a high signal voltage on the IAT signal D A history DTC P1111 will clear after 40 consecutive
circuit. If the intake air is warm, the sensor resistance is warm-up cycles have occurred without a fault.
lower causing the PCM to monitor a lower voltage. DTC D DTC P1111 can be cleared by using the Tech 2 “Clear
P1111 will set when the PCM intermittently detects an Info” function or by disconnecting the PCM battery
feed.
excessively high signal voltage on the intake air
temperature sensor signal circuit. Diagnostic Aids
D Poor connection at PCM –Inspect harness connectors
D The engine has been running for over 4 minutes. for backed-out terminals, improper mating, broken
D Vehicle speed is less than 32 km/h (20 mph). locks, improperly formed or damaged terminals, and
D Engine coolant temperature is above 60°C (140°F). poor terminal-to-wire connection.
D Mass air flow is less than 20g/second. D Damaged harness – Inspect the wiring harness for
D IAT signal voltage indicates and intake air temperature IAT display on the Tech 2 while moving connectors and
intermittently less than –39°C (–38°F) (about 5 volts) wiring harnesses related to the IAT sensor. A change
for approximately 2.5 seconds over a 25-second in the IAT display will indicate the location of the fault.
period of time.
Action Taken When the DTC Sets diagnostic test last failed may help determine how often
D The PCM will substitute a default value for intake air may assist in diagnosing the condition.
temperature.
°C °F OHMS
(approximate)
100 212 177
80 176 332
60 140 667
45 113 1188
35 95 1802
25 77 2796
15 59 4450
5 41 7280
–5 23 12300
–15 5 21450
–30 –22 52700
–40 –40 100700
DTC P1111 –IAT Sensor Circuit Intermittent High Voltage

performed? System
P0113 chart
3 Is DTC P1115, also set? — Go to Step 6 Go to Step 4
4 1. Check for a poor sensor ground circuit terminal
connection at the IAT sensor.
5 1. Check for a poor IAT signal circuit terminal
connection at the IAT sensor.
6 1. Check the IAT signal circuit between the IAT sensor
connector and the PCM for an intermittent open.
voltage.
9 1. Check for an intermittent open or a faulty splice in
the sensor ground circuit.
Refer to

P1112 IAT Sensor Circuit Intermittent Low Voltage
D06RY00168
Circuit Description D The PCM will substitute a default value for intake air
temperature.
The intake air temperature (IAT) sensor is a thermistor
which measures the temperature of the air entering the Conditions for Clearing the MIL/DTC
engine. The powertrain control module (PCM) applies 5
circuit. If the intake air is warm, the sensor resistance Info” function or by disconnecting the PCM battery
feed.
becomes lower, causing the PCM to monitor a lower
voltage. DTC P1112 will set when the PCM intermittently Diagnostic Aids
detects an excessively low signal voltage on the intake air
temperature sensor signal circuit. Check for the following conditions:
D The engine has been running for over 2 minutes. poor terminal-to-wire connection.
D Vehicle speed is greater than 48 km/h (30 mph). D Damaged harness – Inspect the wiring harness for
D IAT signal voltage is greater than 148°C (298°F) damage. If the harness appears to be OK, observe the
(about 0.10 volt) for a total of 2.5 seconds over a IAT display on the Tech 2 while moving connectors and
25-second period of time. wiring harnesses related to the IAT sensor. A change
in the IAT display will indicate the location of the fault.
Action Taken When the DTC Sets Reviewing the Failure Records vehicle mileage since the
D The PCM will not illuminate the malfunction indicator the condition that caused the DTC to be set occurs. This
lamp (MIL).
when the DTC was set as Failure Records data only.
This information will not be stored as Freeze Frame Test Description
data. Number(s) below refer to the step number(s) on the
Diagnostic Chart.
the Failure Records conditions, refer to the
“Temperature vs. Resistance Value Chart.” The
chart may be used to test the IAT sensor at various
the IAT sensor.

°C °F OHMS
(approximate)
100 212 177
80 176 332
60 140 667
45 113 1188
35 95 1802
25 77 2796
15 59 4450
5 41 7280
–5 23 12300
–15 5 21450
–30 –22 52700
–40 –40 100700
DTC P1112 – IAT Sensor Circuit Intermittent Low Voltage

performed? System
— P0112 first Go to Step 3
ground.
Refer to

P1114 ECT Sensor Circuit Intermittent Low Voltage
D06RY00169
when the DTC set as Failure Records data only. This
The engine coolant temperature (ECT) sensor is a information will not be stored as Freeze Frame data.
thermistor mounted in the engine coolant stream. The
powertrain control module (PCM) applies a voltage Conditions for Clearing the MIL/DTC
(about 5.0 volts) through a pull-up resistor to the ECT
signal circuit. When the engine coolant is cold, the sensor D A history DTC P1114 will clear after 40 consecutive
(thermistor) resistance is high, therefore the PCM will
measure a high signal voltage. As the engine coolant D DTC P1114 can be cleared by using the Tech 2 “Clear
warms, the sensor resistance becomes less, and the feed.
ECT signal voltage measured at the PCM drops. With a
fully warmed up engine, the ECT signal voltage should Diagnostic Aids
measure about 1.5 to 2.0 volts. If the PCM detects an Check for the following conditions:
ECT signal that is intermittently below the range of the
ECT sensor, DTC P1114 will set. for backed-out terminals, improper mating, broken
Conditions for Setting the DTC poor terminal-to-wire connection.
D Engine run time longer than 60 seconds. D Damaged harness – Inspect the wiring harness for
D The ECT sensor signal is intermittently greater than damage. If the harness appears to be OK, observe the
150°C (302°F) (about 0.10 volt) for a total of 10 ECT display on the Tech 2 while moving connectors
seconds over a 100-second period. and wiring harnesses related to the ECT sensor. A
change in the ECT display will indicate the location of
Action Taken When the DTC Sets the fault.
D The PCM will not illuminate the malfunction indicator diagnostic test last failed may help determine how often
lamp (MIL).

°C °F OHMS
(approximate)
100 212 177
80 176 332
60 140 667
45 113 1188
35 95 1802
25 77 2796
15 59 4450
5 41 7280
–5 23 12300
–15 5 21450
–30 –22 52700
–40 –40 100700
DTC P1114 – ECT Circuit Intermittent Low Voltage

performed? System
— P0117 first Go to Step 3
3 1. Check the ECT signal circuit between the ECT
sensor connector and the PCM for an intermittent
short to ground.
Refer to

P1115 ECT Sensor Circuit Intermittent High Voltage
D06RY00169
when the DTC was set as Failure Records data only.
The engine coolant temperature (ECT) sensor is a This information will not be stored as Freeze Frame
thermistor mounted in the engine coolant stream. The data.
powertrain control module (PCM) applies a voltage
(about 5.0 volts) through a pull-up resistor to the ECT Conditions for Clearing the MIL/DTC
signal circuit. When the engine coolant is cold, the sensor
(thermistor) resistance is high, therefore the PCM will warm-up cycles have occurred without a fault.
measure a high signal voltage. As the engine coolant
warms, the sensor resistance becomes less, and the Info” function or by disconnecting the PCM battery
ECT signal voltage measured at the PCM drops. With a feed.
fully warmed up engine, the ECT signal voltage should
measure about 1.5 to 2.0 volts. If the PCM detects an Diagnostic Aids
ECT signal that is intermittently above the range of the Check for the following conditions:
ECT sensor, DTC P1115 will set. D Poor connection at PCM – Inspect harness connectors
Conditions for Setting the DTC locks, improperly formed or damaged terminals, and
D Engine running time longer than 90 seconds. poor terminal-to-wire connection.
D The ECT sensor signal is intermittently greater than D Damaged harness – Inspect the wiring harness for
–39°C (–38°F) (about 5 volts) for a total of 10 seconds damage. If the harness appears to be OK, observe the
over a 100-second period. ECT display on the Tech 2 while moving connectors
and wiring harnesses related to the ECT sensor. A
Action Taken When the DTC Sets change in the ECT display will indicate the location of
the fault.
D The PCM will not illuminate the malfunction indicator Reviewing the Failure Records vehicle mileage since the
lamp (MIL). diagnostic test last failed may help determine how often

°C °F OHMS
(approximate)
100 212 177
80 176 332
60 140 667
45 113 1188
35 95 1802
25 77 2796
15 59 4450
5 41 7280
–5 23 12300
–15 5 21450
–30 –22 52700
–40 –40 100700
DTC P1115 – ECT Sensor Circuit Intermittent High Voltage

performed? System
P0118 chart
3 Is DTC P1111 also set? — Go to Step 8 Go to Step 4
connection at the ECT sensor.
5 1. Check for a poor ECT signal circuit terminal
connection at the ECT sensor.
open.
short to voltage.
9 1. Check for an intermittent open or a faulty splice in
the sensor ground circuit.
Refer to

P1120-TPS 1 Throttle Position Sensor (TPS1) Circuit Fault
D06RY00088
Circuit Description D DTC P1120 can be cleared using the Tech 2 “Clear
D The throttle position (TP) sensor circuit provides a feed.
voltage signal relative to throttle blade angle.
The throttle blade angle will vary about 8 % at Diagnostic Aids
closed throttle to about 92 % at wide open An intermittent may be caused by the following:
throttle(WOT).
D Poor connectons.
This code detects a continuous short to ground or D Mis routed harness.
high in either the cicuit or the sensor.
Conditions for setting the DTC D Broken wire inside the insulation.
D The Ignition is “ON”. D Poor connection at PCM-Inspect harness connectors
D The throttle blade angle is less than 2.5 % or more tnan for backed out terminals, improper mating, broken
97.5 % for 18 failres within 500 test samples (15.6m locks, improperly formed or damaged terminals,and
sec) poor terminal to wire connection.
D Damaged harness-Inspect the wiring harness for
Action Taken When the DTC Sets damage. If the harness appears to be OK,observe the
D The PCM will store condition which were present when TPS 1 display on the Tech 2 while moving connectors
the DTC was set as Freeze Frame and in the Failure and wiring harnesses related to the sensor.
Records data. A change in the display will indicate the location of
the fault.
Conditions for Clearing the MIL/DTC If DTC P1120 cannot be duplicated,the
D The PCM will turn the MIL “OFF” on the third information included in the Faillure Records data
consecutive trip cycle during which the diagnostic has can be useful in determined vehicle mileage since
been run and the fault condition is no longer present. the DTC was last set.
D A histror DTC P1120 will clear after 40 cosecutive trip If it is determined that the DTC occurs
cycle during which the warm up cycles have occurred
without a fault. intermittently, performing the DTC P1120
fault.
Diagnostic Trouble Code(DTC)P1120-TPS 1 Circuit Fault

1 Was the “On-Board(OBD)System Check” performed? Go to OBD
System
2 1. Ignition “ON”, engine not running.
2. Observe the MAP reading on the Tech 2.
Is the MAP reading less than the specified value? 65kPa Go to Step 3 Go to Step 6
3 1. Disconnect the MAP sensor.
2. Connect a test 5 volt reference circuit and the MAP
signal at the MAP sensor harness connector.
Is the MAP reading less than the specified value? (If no,
start with diagnosis chart forother sensors in the circuit
and see if 5V returns.) — Go to Step 5 Go to Step 4
4 1. Check the MAP signal circuit between the PCM and
MAP grund circuit.
2. If the MAP signal circuit is open or shoted, repair it
as necessary.
Was the MAP signal circuit open or shorted? — Verify repair Go to Step 12
6 Observe the TP angle reading on the Tech 2 while
slowly opening the throttle. Closed
Does the TP angle increase steadily and evenly from throttle =8 % Refer to
the closed throttle value to the wide open throttle Wide open Diagnostic
value? throttle =92 % Aids Go to Step 7
7 1. Disconnect the TP sensor.
2. Observe the TP sensor reading on the Tech 2.
Is the TP sensor reading near the specified value? 0V Go to Step 8 Go to Step 9
8 1. Connect a test light between the 5Volt reference
circuit and the TP1 sensor signal circuit at the TP1
2. Observe the TP1 sensor reading on the Tech 2.
1. TP1 signal circuit for a short to voltage.
2. TP1 sensor ground circuit for high resistance
between the PCM and the TP sensor.
3. TP1 sensor ground circuit for a poor connection.
necessary.
Diagnostic Trouble Code(DTC)P1120-TPS 1 Circuit Fault (Cont'd)

1. TP signal circuit or 5 volt reference circuit for a poor
connection.
2. TP signal circuit or 5 volt reference circuit for high
resistance between the PCM and the TP sensor.
3. If a problem is found, repair wiring harness as
necessary.
11 Replace the TP sensor.
12 Replace the PCM.
programmed.
SOFTWARE to the replasement PCM.

P1125 ETC (Electric Throttle Control) Limit Performance Mode
D06RY00157

D The acceleration position (AP1) sensor circuit provides An intermittent may be caused by the following:
a voltage signal relative to acceleration pedal angle. D Poor connectons.
The acceleration pedal angle will vary about 13 % D Mis routed harness.
at idle position to about 87 % at wide open throttle D Rubbed through wire insulation.
(WOT). D Broken wire inside the insulation.
This code detects if the systm is in Limit Check for the following conditions:
Performance Mode. (Fail safe Mode) D Poor connection at PCM-Inspect harness connectors
Conditions for setting the DTC locks, improperly formed or damaged terminals,and
D The Ignition is “ ON”.
D Limit Performance Mode is active. (Fail safe Mode) damage. If the harness appears to be OK, observe the
APP sensor 1, APP sensor 2, APP sensor 3 display on
Action Taken When the DTC Sets the Tech 2 While moving connectors and wiring
D The PCM will store condition which were present when harnesses related to the sensor.
the DTC was set as Freeze Frame and in the Failure A change in the display will indicate the location of
Records data. the fault.
If DTC P1125 cannot be duplicated,the
Conditions for Clearing the MIL/DTC information includedin the Faillure Records data
D The PCM will turn the MIL “OFF” on the third can be useful in determined vehicle mileage since
consecutive trip cycle during which the diagnostic has the DTC was last set.
been run and the fault condtion is no longer present.
cycle during which the warm up cycles have occurred intermittently,performing the DTC P1125
without a fault. Diagnostic Chart may isolate the cause of the
fault.
D DTC P1125 can be cleared using the Tech 2 “Clear
feed.
DTC P1125 – ETC Limit Performance Model

System
2 Was the “Electric Throttle Control (ETC) System Go to ETC
Chcek” performed? System
3 Observe the AP angle reading on the Tech 2 while Idle position
slowly opening the throttle. APP sensor 1
Does the AP angle increase steadily and evenly from =13 % APP
the closed throttle value to the wide open throttle sensor 2, 3
value? =85 ∼ 89 %
open throttle
APP sensor 1
=85 ∼ 89 % Refer to
APP sensor 2 Diagnostic
=11 ∼ 15 % Aids Go to Step 4
4 1. Disconnect the AP sensor.
2. Observe the AP sensor reading on the Tech 2.
Is the AP sensor reading near the specified value? 0V Go to Step 5 Go to Step 6
5 1. Connect a test light between the 5 Voltge supply
circuit and the AP1, AP2 AND AP3 sensor signal
circuit at the AP sensor harness connector.
1. AP1, AP2 or AP3 signal circuit for a short to voltage.
2. AP1, AP2 or AP3 sensor ground circuit for high
resistance between the PCM and the AP sensor.
3. AP1, AP2 or AP3 sensor ground circuit for a poor
connection.
necessary.
1. AP1, AP2 or AP3 signal circuit or 5 volge supply
circuit for a poor connection.
2. AP1, AP2 or AP3 signal circuit or 5 volge supply
circuit for high resistance between the PCM and the
AP1, AP2 or AP3 sensor.
necessary.
DTC P1125 – ETC Limit Performance Model (Cont'd)

8 Replace the AP sensor.
9 Replace the PCM.
programmed.Refer to ON-Vehicle Service in Power

P1133 HO2S Insufficient Switching Bank 1 Sensor 1
D06RY00171
Circuit Description D Canister purge duty cycle is greater than 2%.

The powertrain control module (PCM) monitors the D Engine speed is between 1500 RPM and 3000 RPM.
heated oxygen sensor (HO2S) activity for 90 seconds D Mass air flow (MAF) is between 9 g/second and 42
after “closed loop” and stoichiometric operation have g/second.
been enabled. During this test period the PCM counts the D Above conditions are present for 3 seconds.
number of times that the HO2S signal voltage crosses the D 90 seconds after “closed loop” and stoichiometric
rich-to-lean and lean-to-rich threshold. If the PCM operation have been achieved, the PCM monitors the
determines that the HO2S did not switch enough times, oxygen sensor as it switches above and below 450 mV.
DTC P1133 will be set. If fewer than 23 rich-to-lean and lean-to-rich switches
are detected, DTC P1133 will be set.
A lean-to-rich switch is determined when the HO2S
voltage changes above and below 450 mV. Action Taken When the DTC Sets
of time required for “closed loop” fuel control operation D The PCM will illuminate the malfunction indicator lamp
and to allow accurate catalyst monitoring. The oxygen fault is detected.
sensor heater greatly decreases the amount of time
D ”Open loop” fuel control will be in effect.
required for fuel control sensors Bank 1 HO2S 1 and Bank
2 HO2S 1 to become active. Oxygen sensor heaters are D The PCM will store conditions which were present
required by post-catalyst monitor sensors to maintain a Failure Records data.
sufficiently high temperature for accurate exhaust oxygen
content readings further from the engine. Conditions for Clearing the MIL/DTC
D Engine coolant temperature (ECT) is above 50°C been run and the fault condition is no longer present.
(122°F) for automatic transmission; 75°C (167°F) for D A history DTC P1133 will clear after 40 consecutive
manual transmission. warm-up cycles have occurred without a fault.
D Engine is operating in “closed loop”. D DTC P1133 can be cleared by using Tech 2 “Clear Info”
D The engine has been running at least one minute. function or by disconnecting the PCM battery feed.
Diagnostic Aids 3. A condition that affects other heated oxygen sensors
A malfunction in the HO2S heater ignition feed or ground indicates probable contamination. To avoid
damaging the replacement sensors, correct the
circuit may cause a DTC P1133 to set. Check HO2S
condition which caused the contamination before
heater circuitry for intermittent faults or poor connections.
replacing the affected sensors.
If connections and wiring are OK and DTC P1133
continues to set, replace the Bank 1 HO2S 1. 5. This step checks for conditions which may cause the
Reviewing the Failure Records vehicle mileage since the heated oxygen sensor to appear faulty. Correct any
diagnostic test last failed may help to determine how often of the described conditions if present.
the condition that caused the DTC to be set occurs. This 11.To avoid damaging replacement sensors, correct the
may assist in diagnosing the condition. condition which caused the contamination before
Test Description
Diagnostic Chart.
DTC P1133 – HO2S Insufficient Switching Bank 1 Sensor 1

performed? System
2 IMPORTANT: If any DTCs are set (except P1153 or
P1154) refer to those DTCs before proceeding with this
diagnostic chart.
1. Engine idling at operating temperature.
2. Operating the vehicle within parameters specified
3 Did the Tech 2 also indicate that the P1153 or P1154
tests failed? — Go to Step 20 Go to Step 4
4 Check for leaks at the exhaust pipe joints.
5 Tighten the bolt/nuts at the leaking joints.
installed.
DTC P1133 – HO2S Insufficient Switching Bank 1 Sensor 1 (Cont'd)

installed.
D Check for corrosion on the terminals.
D Check the terminals at Bank 1 HO2S 1 and at the
PCM.
Was a problem found in any of the above areas? — Verify repair Go to Step 15
3. Using a DVM at the PCM side of the connector,
check the voltage between the high signal circuit
and ground. Also measure between the low signal
circuit and ground.
Are both voltages in the specified range? 3-4 mV Go to Step 18 Go to Step 16
2. Check for damage to PCM pins or terminals.
Was a problem found. — Verify repair Go to Step 17
17 Check for a short to voltage or ground or an open in the
signal circuit.
3. With the HO2S disconnected, check for high and
low signal circuits shorted together between the
PCM and HO2S.
19 With the PCM connected and Bank 1 HO2S 1
disconnected from the harness, check Bank 1 HO2S 1
with a Tech 2.
Is the voltage in the specified range? 425-475 mV Go to Step 21 Go to Step 22
NOTE: Before replacing the sensors, the cause of the
D Fuel contamination

22 Replace the PCM.
procedures.
Is the action compete? — Verify repair —

P1134 HO2S Transition Time Ratio Bank 1 Sensor 1
D06RY00171
Circuit Description D Above conditions are present for a 3-second

monitoring period.
The powertrain control module (PCM) monitors the
heated oxygen sensor (HO2S) activity for 90 seconds D 90 seconds after “closed loop” and stoichiometric
operation have been enabled, Bank 1 HO2S 1
after “closed loop” and stoichiometric operation have transition ratio between lean-to-rich and rich-to-lean is
been established. During the monitoring period the PCM less than 0.44 or greater than 3.8.
counts the number of times that the HO2S responds from
rich-to-lean and from lean-to-rich and adds the amount of Action Taken When the DTC Sets
time it took to complete all transitions. With this
information, an average time for all transitions can be (MIL) after second consecutive trip in which the fault is
determined. The PCM then divides the rich-to-lean detected.
average by the lean-to-rich average to obtain a ratio. If D ”Open loop” fuel control will be in effect.
the HO2S transition time ratio is not within this range, D The PCM will store conditions which were present
DTC P1134 will be set, indicating that the oxygen sensor when the DTC was set as Freeze Frame and in the
is not responding as expected to changes in exhaust Failure Records data.
oxygen content.
D No related DTCs. consecutive trip cycle during which the diagnostic has
D Engine coolant temperature (ECT) is above 50°C been run and the fault condition is no longer present.
(122°F) for automatic transmission; 75°C (167°F) for D A history DTC P1134 will clear after 40 consecutive
manual transmission. warm-up cycles have occurred without a fault.
D Engine is operating in “closed loop.” D DTC P1134 can be cleared by using the Tech 2 “Clear
D The engine has been running at least one minute. Info” function or by disconnecting the PCM battery
feed.
D Engine speed is between 1500 RPM and 3000 RPM. Diagnostic Aids
D Mass air flow (MAF) is between 9 g/second and 42 A malfunction in the HO2S heater ignition feed or ground
g/second.
heater circuitry for intermittent faults or poor connections. 3. A condition that affects other heated oxygen sensors
If connections and wiring are OK and DTC P1134 indicates probable contamination. To avoid
continues to set, replace the Bank 1 HO2S 1. damaging replacement sensors, correct the
Reviewing the Failure Records vehicle mileage since the condition which caused the contamination before
diagnostic test last failed may help determine how often replacing the affected sensors.
the condition that caused the DTC to be set occurs. This 5. This step checks for conditions which may cause the
may assist in diagnosing the condition. heated oxygen sensor to appear faulty. Correct any
of the described conditions if present.
Test Description 8. To avoid damaging replacement sensors, correct the
Number(s) below refer to the step number(s) on the condition which caused the contamination before
Diagnostic Chart. replacing the affected sensors.
DTC P1134 – HO2S Transition Time Ratio Bank 1 Sensor 1

performed? System
2 IMPORTANT: If any DTCs are set (except P1153
and/or P1154), refer to those DTCs before proceeding
with this diagnostic chart.
Refer to
4. Note the test result. Diagnostic
Does Tech 2 indicate DTC 1134 failed this ignition? — Go to Step 3 Aids
3 Did the Tech 2 also indicate P1153, and/or P1154 test
failed? — Go to Step 17 Go to Step 4
5 Tighten the U-bolt nuts at the leaking joints.
installed.
DTC P1134 – HO2S Transition Time Ratio Bank 1 Sensor 1 (Cont'd)

installed.
D Check the terminal tension (at Bank 1 HO2S 1
and at the PCM).
4. Also measure the voltage between the low signal
circuit and ground.
Are both voltages in the specified range? 3-4V Go to Step 16 Go to Step 19
17 Replace affected heated oxygen sensors.

22 Replace the PCM.
procedures.

P1153 HO2S Insufficient Switching Bank 2 Sensor 1
D06RY00175
Circuit Description D Canister purge duty cycle is greater than 2%.

The powertrain control module (PCM) monitors the D Engine speed is between 1500 RPM and 3000 RPM.
heated oxygen sensor (HO2S) activity for 90 seconds D Mass air flow is between 9 g/second and 42 g/second.
after “closed loop” and stoichiometric operation have D Above conditions are present for a 3 seconds.
been enabled. During this test period the PCM counts the D 90 seconds after “closed loop” and stoichiometric
number of times that the HO2S signal voltage crosses the operation have been enabled, the PCM monitors the
rich-to-lean and lean-to-rich thresholds. If the PCM oxygen sensor switching above and below 450 mV. If
determines that the HO2S did not switch enough times, fewer than 27 rich-to-lean and lean-to-rich switches for
DTC P1153 will be set. Bank 2 HO2S 1 are detected, DTC P1153 will set.
A lean-to-rich switch is determined when the HO2S Action Taken When the DTC Sets
voltage changes above and below 450 mV.
Heated oxygen sensors are used to minimize the amount D The PCM will illuminate the malfunction indicator lamp
of time required for “closed loop” fuel control operation (MIL) after the second consecutive trip in which the
fault is detected.
sensor heater greatly decreases the amount of time D ”Open loop” fuel control will be in effect.
required for fuel control sensors Bank 1 HO2S 1 and Bank D The PCM will store conditions which were present
2 HO2S 1 to become active. Oxygen sensor heaters are when the DTC was set as Freeze Frame and in the
required by post-catalyst monitor sensors to maintain a
sufficiently high temperature for accurate exhaust oxygen Conditions for Clearing the MIL/DTC
content readings further from the engine.
Conditions for Setting the DTC consecutive trip cycle during which the diagnostic has
D The engine is operating in “closed loop.” D A history DTC P1153 will clear after 40 consecutive
D Engine coolant temperature (ECT) is above 50°C warm-up cycles have occurred without a fault.
D The engine has been running at least one minute. feed.
Diagnostic Aids 3. A condition that affects other heated oxygen sensors
A malfunction in the HO2S heater ignition feed or ground indicates probable contamination. To avoid
damaging replacement sensors, correct the
heater circuitry for intermittent faults or poor connections.
If connections and wiring are OK and DTC P1153
continues to set, replace the Bank 2 HO2S 1. 5. This step checks for conditions which may cause the
Reviewing the Failure Records vehicle mileage since the heated oxygen sensor to appear faulty. Correct any
diagnostic test last failed may help determine how often of the described conditions if present.
the condition that caused the DTC to be set occurs. This 8. To avoid damaging replacement sensors, correct the
may assist in diagnosing the condition. condition which caused the contamination before
Test Description
Diagnostic Chart.
DTC P1153 – HO2S Insufficient Switching Bank 2 Sensor 1

performed? System
2 IMPORTANT: If any DTCs are set, (except P1133
Refer to
Note the test result.
Diagnostic
Does Tech 2 indicate DTC failed this ignition? — Go to Step 3 Aids
3 Did the Tech 2 also indicate P1133 and/or P1134 test
installed.

installed.
D Check the terminal tension at Bank 2 HO2S 1 and
at the PCM.
Was a problem found in any of the above areas? — Verify repair Go to Step 15
check the voltage between the high signal circuit
and ground. Also measure between the low signal
circuit and ground.
Are both voltages in the specified range? 3-4V Go to Step 18 Go to Step 16
2. Check for damage to PCM pins or terminals.
17 Check for short to voltage or ground or an open in the
signal circuit.
3. With HO2S disconnected, check for high and low
signal circuits shorted together between the PCM
and HO2S.
19 With the PCM connected and Bank 2 HO2S 1
disconnected from the harness, check Bank 2 HO2S 1
with a Tech 2.
Is the voltage in the specified range? 425-475 mV Go to Step 21 Go to Step 22

22 Replace the PCM.
procedures.

P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1
D06RY00175
Circuit Description D 90 seconds after “closed loop” and stoichiometric

operation have been enabled, Bank 2 HO2S 1
The powertrain control module (PCM) monitors the transition ratio between lean to rich and rich to lean is
heated oxygen sensor (HO2S) activity for 90 seconds less than 0.44 or greater than 3.8.
after “closed loop” and stoichiometric operation have
been enabled. During the monitor period the PCM counts Action Taken When the DTC Sets
the number of times that the HO2S responds from
rich-to-lean and from lean-to-rich and adds the amount of (MIL) after the second consecutive trip in which the
time it took to complete all transitions. With this fault is detected.
information, an average time for all transitions can be D ”Open loop” fuel control will be in effect.
determined. The PCM then divides the rich-to-lean
average by the lean-to-rich average to obtain a ratio. If when the DTC was set as Freeze Frame and in the
the HO2S transition time ratio is not within this range, Failure Records data.
DTC P1154 will be set, indicating that the oxygen sensor
is not responding as expected to changes in exhaust Conditions for Clearing the MIL/DTC
oxygen content. D The PCM will turn the MIL “OFF” on the third
D Engine coolant temperature (ETC) is above 50°C warm-up cycles have occurred without a fault.
D The engine is operating in “closed loop.” feed.
D The engine has been running at least one minute.
Diagnostic Aids
A multifunction in the HO2S heater ignition feed or ground
D Mass air flow is between 9 g/second and 42 g/second. heater circuitry for intermittent faults or poor connections.
D Above conditions are present for a 3-second If connections and wiring are OK and DTC P1154
monitoring period.
continues to set, replace the Bank 2 HO2S 1.
Reviewing the Failure Records vehicle mileage since the 5. This step checks for conditions which may cause the
diagnostic test last failed may help determine how often heated oxygen sensor to appear faulty. Correct any
the condition that caused the DTC to be set occurs. This of the described conditions if present.
may assist in diagnosing the condition. 8. To avoid damaging replacement sensors, correct the
Test Description replacing the affected sensors.
Diagnostic Chart.
3. A condition that affects other heated oxygen sensors
indicates probable contamination. To avoid
damaging replacement sensors, correct the
DTC P1154 – HO2S Transition Time Ratio Bank 2 Sensor 1

performed? System
2 IMPORTANT: If any other DTCs are set (except P1133
Refer to
Note the test result.
Diagnostic
Does Tech 2 indicate DTC failed this ignition? — Go to Step 3 Aids
3 Did the Tech 2 also indicate P1133, and/or P1134 test
installed.

installed.
D Check terminal tension (at Bank 2 HO2S 1 and at
the PCM).
Also measure the voltage between the low signal
circuit and ground.
Go to Step
Are both voltages in the specified range? 3-4 V 16 Go to Step 19

22 Replace the PCM.
procedures.

P1167 Fuel System Rich During Decel Fuel Cut Off (Bank 1)
D06RY00171

The powertrain control module (PCM) continuously D The PCM will not illuminate the malfunction
monitors the heated oxygen sensor (HO2S) activity for 90 malfunction indicator lamp (MIL).
seconds after “closed loop” has been enabled. During the D The PCM will store condition which were present when
monitoring period the powertrain control module (PCM) the DTC was set as Freeze Frame and in the Failure
counts the number of times a rich to lean and respones is Records data.
indicated and adds the amountof time it look to complete
all rich to lean transisitions and lean to rich transitions. Conditions for Clearing the MIL/DTC
This code detects if Bank1 02 sensor indicated rich D A history DTC P1167 will clear after 40 cosecutive trip
exhaust while in Decel Fuel Cut Off (DFCO) for fuel cycle during which the warm up cycles have occurred
control sensors. without a fault.
Conditions for setting the DTC Info” function or by disconnecting the PCM battery
feed.
D No related DTCs.
D The engine coolant temperature is more than 60 °C Diagnostic Aids
(140 °F).
D Engine is operating in “closed loop” power enrichment D Check for faulty fuel injectors and fuel pump.
mode for 3 secondes.
D While in “power enrichment” mode the oxygen sensor
voltage remains more than 600mV in DFCO.

P1167 Fuel System Rich During Decel Fuel Cut Off (Bank1)
System
2 Are any component related DTCs set? Go to
component
DTC charts Go to Step 3
3 1. Place the transmission in Park.
2. Using a Tech 2, HO2S 1 voltage while running warm
engine 75 °C – 95 °C (167 °F – 203 °F) at 1200
RPM.
3. HO2S 1 votages should vary within the specified
range. (100 – 900mV)
4. Quickly open the wide open the throtle for a few Go to OBD
Did the voltage suddenly rise toward the low endof the System
specified range? 100 – 600 mV Check Go to Step 4
4 1. Disconnect the fuel pump relay and crank the
engine to relieve the fuel pressure.
2. Install the fuel pressure gauge.
3. Start the engine and idle at normal operating
temperatur.
4. Disconnect the vacuum line going to the fuel
pressure regurlator. Go to OBD
With the engine running, is the fuel pressure within the 280 – 325Kpa System
specified range? (41 – 46psi) Check Go to Step 5
2. Remove the fuel pump relay and replace it with a
fused jumper which will connect the relay’s battery
terminal to the terminal leading to the fuel pump
fuse.
3. While the fuel pump is opreating, use pliers to slowly
close the return line (do not exceed the first
specified value).
Using the pliers to restrict the return line, can the 414KPa
fuel pressure be manipulated to exceed the (60psi) Refer to
second value?
325KPa Diagnostic
Is the TP sensor reading near the specified value? (46psi) Aids Go to Step 6
D Faulty fuel pump
D Incorrect fuel pump
D Incorrect fuel being used
D Cold fuel
If a problem is found, repair one as necessary.

P1169 Fuel System Rich During Decel Fuel Cut Off (Bank 2)
D06RY00175
Circuit Description D While in “power enrichment” mode the oxygen sensor

voltage remains more than 600mV in DFCO.
The powertrain control module(PCM)
continuously monitors the heated oxygen sensor (HO2S) Action Taken When the DTC Sets
activity for 90 seconds after “closed loop” has been
enabled. During the monitoring period the powertrain D The PCM will not illuminate the malfunction
control module (PCM) counts the number of times a rich malfunction indicator lamp(MIL).
to lean and respones is indicated and adds the amountof D The PCM will store condition which were present when
time it look to complete all rich to lean transisitions and the DTC was set as Freeze Frame and in the Failure
Records data.
lean to rich transitions.
This code detects if Bank2 sensor indicated rich exhaust Conditions for Clearing the MIL/DTC
while in Decel Fuel Cut Off (DFCO) for fuel control
sensors. D A history DTC P1169 will clear after 40 cosecutive trip
without a fault.
D No related DTCs. Info” function or by disconnecting the PCM battery
D The engine coolant temperature is more than 60 °C feed.
(140 °F).
D Engine is operating in “closed loop” power enrichment Diagnostic Aids
mode for 3 secondes. D Check for faulty fuel injectors and fuel pump.

P1169 Fuel System Rich During Decel Fuel Cut Off (Bank2)
System
2 Are any component related DTCs set? Go to
component
DTC charts Go to Step 3
3 1. Place the transmission in Park.
2. Using a Tech 2, HO2S 2 voltage while running warm
engine75 C – 95 C (167 F – 203 F) at 1200 RPM.
3. HO2S 1 votages should vary within the specified
range. (100 – 900mV)
4. Quickly open the wide open the throtle for a few Go to OBD
Did the voltage suddenly rise toward the low end of the System
specified range? 100 – 600 mV Check Go to Step 4
temperatur.
pressure regurlator. Go to OBD
With the engine running, is the fuel pressure within the 280 – 325Kpa System
specified range? (41 – 46psi) Check Go to Step 5
fuse.
3. While the fuel pump is opreating, use pliers to slowly
specified value). 414KPa
Using the pliers to restrict the return line, can the fuel (60psi) Refer to
pressure be manipulated to exceed the second value? 325KPa Diagnostic
Is the TP sensor reading near the specified value? (46psi) Aids Go to Step 6
D Faulty fuel pump
D Cold fuel.
If a problem is found, repair one as necessary.
Diagnostic Trouble Code (DTC) P1171 Fuel System Lean During Acceleration
D06RY00175

The powertrain control module (PCM) internal circuitry D The PCM will illuminate the malfunction indicator lamp
can identify if the vehicle fuel system is capable of (MIL) the first the fault is detected.
supplying adequate amounts of fuel during heavy D The PCM will store conditions which were present
acceleration (power enrichment). The PCM monitors the when the DTC was set as Freeze Frame and in the
voltage of the oxygen sensor during power enrichment. Failure Records data.
When a power enrichment mode of operation is
requested during “closed loop” operation (by heavy Conditions for Clearing the MIL/DTC
acceleration), the PCM will provide more fuel to the D The PCM will turn the MIL “OFF” on the third
engine. Under these conditions the PCM should detect a consecutive trip cycle during which the diagnostic has
“rich” condition (high oxygen sensor voltage). If this “rich” been run and the fault condition is no longer present.
exhaust is not detected at this time, a DTC P1171 will set. D A history DTC P1171 will clear after 40 consecutive
A plugged fuel filter, restricted fuel line, restricted in-tank warm-up cycles have occurred without a fault.
filter or defective fuel pump can prevent adequate D DTC P1171 can be cleared by using the Tech 2 “Clear
amounts of fuel from being supplied during power Info” function or by disconnecting the PCM battery
enrichment mode. feed.
Conditions for Setting the DTC Diagnostic Aids

D No related DTCs. D A restricted fuel filter or fuel line, restricted in-tank filter,
or a defective fuel pump may supply adequate
D Engine is operating in “closed loop power enrichment” amounts of fuel at idle, but may not be able to supply
mode for 3 seconds. enough fuel during heavy acceleration.
D Engine coolant temperature is above 60°C (140°F). D Water or alcohol in the fuel may cause low HO2S
D While in “power enrichment” mode the oxygen sensor voltage during acceleration.
voltage remains below 400 mV for 3 seconds. D Check for faulty or plugged fuel injector(s).
D Check for low fuel.
Test Description
Diagnostic Chart.
4. When the engine is idling or at steady cruise, the
HO2S voltage should vary from between
approximately 100 mV to 900 mV. It is possible to
measure a satisfactory fuel pressure at idle even
though the pressure may drop at high flow
requirements. It may be necessary to watch fuel
pressure at high engine load.
5. Wrap a shop towel around the fuel pressure
connector to absorb any small amount of fuel
leakage that may occur when installing gauge.
Ignition “ON,” pump pressure should be 280-320
kPa.
7. Add Caution, Use correct pliers so damage to fuel
lines will not occur.
DTC P1171 – Fuel System Lean During Acceleration

performed? System
2 Are any component-related DTCs set? Go to
component
— DTC charts Go to Step 3
3 1. Check the vehicle’s fuel tank for an adequate
amount of fuel.
2. Add fuel to the vehicle’s fuel tank if the tank is almost
empty.
Was fuel added to the vehicle’s fuel tank? — Go to Step 4 Go to Step 5
4 1. Place the transmission in park.
2. Using a Tech 2, observe HO2S 1 voltage while
running warm engine 75°C-95°C (167°F-203°F) at
1200 RPM.
3. HO2S 1 voltage should vary within the specified
range.
4. Quickly open the throttle halfway for a few seconds. Go to Fuel
Did the voltage suddenly rise toward the high end of the System
specified range? 100-900 mV Electrical Test Go to Step 5
temperature.
pressure regulator. Go to OBD
With the engine running, is the fuel pressure within the 280-325 kPa System
specified range? (41-46 psi) Check Go to Step 6
6 Check for restricted fuel lines or restricted in-line filter.
fuse.
3. While the fuel pump is operating, use pliers to slowly
specified value). 414 kPa
Using the pliers to restrict the return line, can the fuel (60 psi) Go to
pressure be manipulated to exceed the second 325 kPa Diagnostic
specified value? (46 psi) Aids Go to Step 8
8 Check for:
D Faulty fuel pump
D Restricted fuel pump strainer (sock)
D Hot fuel

P1220 Throttle Position Senser2 (TPS2) Circuit Fault
D06RY00088
Circuit Description D DTC P1120 can be cleared using the Tech2 “Clear Info”
function or by disconnecting the PCM battery feed.
D The throttle position (TP2) sensor circuit provides a
voltage signal relative to throttle blade angle. Diagnostic Aids
The throttle blade angle will vary about 92 % at
An intermittent may be caused by the following:
closed throttle to about 8 % at wide open throttle
(WOT). D Poor connectons.
This code detects a continuous short to ground or
high in either the cicuit or the sensor. D Rubbed through wire insulation.
D Broken wire inside the insulation.
Conditions for setting the DTC Check for the following conditions:
D The MAP sensor shares a 5 Volt reference with the
D The Ignition is “ON”. Fuel Tank Pressure.If these codes are also set, it could
D The throttle blade angle is less than 2.5 % or more tnan indicate a problem with the 5 Volt reference circuit.
97.5 % for 18 failres within 500 test samples (15.6m D The MAP sensor shares a ground with the Fuel Tank
sec). Pressure,the ECT sensor,and the Transmission Fluid
Action Taken When the DTC Sets D Poor connection at PCM-Inspect harness connectors
for backed out terminals,improper mating,broken
D The PCM will store condition which were present when locks, improperly formed or damaged terminals,and
the DTC was set as Freeze Frame and in the Failure poor terminal to wire connection.
Records data. D Damaged harness–Inspect the wiring harness for
damage. If the harness appears to be OK,observe the
Conditions for Clearing the MIL/DTC TP sensor display on the Tech 2 while moving
D The PCM will turn the MIL “OFF” on the third connectors and wiring harnesses related to the sensor.
consecutive trip cycle during which the diagnostic has A change in the display will indicate the location of
been run and the fault condtion is no longer present. the fault. If DTC P1120 cannot be duplicated,the
D A history DTC P1120 will clear after 40 consecutive trip information included in the Faillure Records data
cycle during which the warm up cycles have occurred can be useful in determined vehicle mileage since
without a fault. the DTC was last set.
intermittently,performing the DTC
P1120 Diagnostic Chart may isolate the cause of the fault.
DTC P1220-TPS 2 Circuit Fault

System
Check” performed? System
Is the MAP reading less than the specified value? 65 kPa Go to Step 4 Go to Step 7
start with diagnosis chart for other sensors in the circuit
MAP ground circuit.
2. If the MAP signal circuit is open or shorted, repair as
necessary.
7 Observe the TP angle reading on the Tech-2 while Closed TP
slowly opening the throttle. sensor 1 =8 ∼
Does the TP angle increase steadily and evenly from 10 % TP
the closed throttle value to the wide open throttle sensor 2 =90
value? ∼ 92 % Wide
open TP
sensor 1 =90
∼ 92 % TP Refer to
sensor 2 =8 ∼ Diagnostic
10 % Aids Go to Step 8
2. Observe the TP sensor reading on the Tech2.
circuit and the TP2 sensor signal circuit at the
TPsensor harness connector.
DTC P1220-TPS 2 Circuit Fault (Cont'd)

1. TP2 signal circuit for a short to voltage.
2. TP2 sensor ground circuit for high resistance
between the PCM and the TP2 sensor.
3. TP2 sensor ground circuit for a poor connection.
necessary.
1. TP2 signal circuit or 5 volt reference circuit for a
poor connection.
2. TP2 signal circuit or 5 volt reference circuit for high
necessary.
13 Replace the PCM.
Diagnosis Truble Code(DTC)

P1221 TPS1 – TPS2 correlation(Circuit Performance)
D06RY00157
Circuit Description 2. Visually/physically inspect for the following throttle

valve conditions.
D The powertrain control module (PCM) controls engine
speed by adjusting the position of the throttle control 3.Visually/physically inspect for the following
valve (DC motor). The throttle motor is a DC motor acceleration pedal conditions.
driven by one coil. The PCM applies current to DC 5.Check the following circuits for throttle valve and DC
motor coil in steps (%) to adjustment the valve into a
passage in the throttle body to air flow. moter. Check the following TP sensor resistance
and DC motor.
This method allows highly accurate control of
engine speed and quick response to changes in 7.Check the following circuits for acceleration pedal.
engine load. Check the following AP sensor resistance.
D The acceleration position (AP) sensor circuit provides 9.Following DTC: Software detect Error for ETC
a voltage signal relative to acceleration pedal angle. system.
The acceleration pedal angle (AP1) will vary about 10.Following DTC: Software detect Error for ETC
13% at idle position to about 87% at open system.
throttle(WOT).
APS signal is used to determine which DC will Diagnostic Aids
adjusting throttle position. D An intermittent may be caused by a poor connection,
After the APS signal has been processed by the rubbed–through wire insulation or a wire broken inside
PCM, it will command DC motor to allow a move the insulation. Check for poor connections or a
of throttle position. damaged harness. Inspect the PCM harness and
connector for improper mating, broken locks,
D Acceleration pedal – Check for objects blocking the AP improperly formed or damaged terminals, poor
sensor or pedal arm with spring, and excessive terminal-to-wire connection, and damaged
deposits in the acceleration pedal arm and on the harness.
acceleration pedal. D Throttle body – Check for objects blocking the DC
motor or throttle bore, excessive deposits in the ETC
Test Description passage and on the valve spring, and excessive
Number(s) below refer to the step number(s) on the deposits in the throttle bore and on the throttle valve
Diagnostic Chart: plate.

P1221 TPS1 – TPS2 correlation(Circuit Perfoemance)
1 Was the “On-Board (OBD) System Check”performed? Go to OBD
System
intake system.
Refer to
appropriate
section for
play
on–vehicle
D Acceleration pedal : Check for objects blocking
Refer to
appropriate
section for
excessive play.
on–vehicle
harness connector.
necessary.
6 1. Check the following circuits for an open, short to
PCM:
Throttle position sensor 1 circuit.
Throttle position sensor 2 circuit.
Throttle DC motor circuit. Vcc-GND
Throttle position sensor resistance. 1–7kW
Throttle DC motor resistance. SIG-DND
change
2. If a problem is found, repair as necessary. resistance 0.3
Was a problem found? – 100W Verify repair Go to Step 7

P1221 TPS1 – TPS2 correlation(Circuit Perfoemance) (Cont'd)
8 1. Check the following circuits for an open, short to
PCM:
D C position sensor 3 circuit.
D V position sensor resistance.
Go to
P1125, P1290, P1295, P1299
applicable
Go to
P1514, P1515, P1516, P1523, P1271, P1272, P1273
applicable
12 Replace the PCM.
programmed.
Diagnostic Trouble Code (DTC) P1271 APS 1– 2 Correlation Error
D06RY00075
D The acceleration position (AP) sensor circuit provides feed.
a voltage signal relative to acceleration pedal angle.
The acceleration pedal angle (AP1) will vary about Diagnostic Aids
13 % at idle position to about 87 % at wide open An intermittent may be caused by the following:
throttle(WOT).
D Poor connectons.
This code detects a correlation error between D Mis routed harness.
APS1 and APS2.
D The acceleration pedal angle difference is less than 4.5 for backed out terminals, improper mating, broken
% between ASP1 and APS2 for 50 counts within 50 locks, improperly formed or damaged terminals, and
test samples (15.6 m sec). poor terminal to wire connection.
Action Taken When the DTC Sets damage. If the harness appears to be OK, observe the
D The PCM will store condition which were present when APP sensor 1, APP sensor 2 display on the Tech 2
the DTC was set as Freeze Frame and in the Failure while moving connectors and wiring harnesses related
Records data. to the sensor.
Conditions for Clearing the MIL/DTC the fault. If DTC P1271 cannot be duplicated,the
D A history DTC P1271 will clear after 40 consecutive trip If it is determined that the DTC occurs
cycle during which the warm up cycles have occurred intermittently, performing the DTCP1271
without a fault. Diagnostic Chart may isolate the cause of the
fault.
DTC P1271 – APS 1– 2 Correlation Error

System
open throttle
APP sensor 1
=85 ∼ 89 % Refer to
circuit and the AP sensor signal circuit at the AP1,
AP2 sensor harness connector.
1. AP1and AP2 signal circuit for a short to voltage.
2. AP1and AP2 sensor ground circuit for high
3. AP1and AP2 sensor ground circuit for a poor
connection.
necessary.
1. AP1and AP2 signal circuit or 5 volge supply circuit
for a poor connection.
2. AP1and AP2 signal circuit or 5 volge supply circuit
for high resistance between the PCM and the AP1
and AP2 sensor.
necessary.
DTC P1271 – APS 1– 2 Correlation Error (Cont'd)

9 Replace the PCM.
programmed.
if the latest software is released ornot. And then Down
Load the LATEST PROGRAMMED SOFTWARE to the
replasement PCM.
Diagnostic Trouble Code (DTC) P1272 APS 2 – 3 Correlation Error
D06RY00075
throttle (WOT).
D Poor connectons.
This code detects a correlation error D Mis routed harness.
betweenAPS2 and APS3.
D The acceleration pedal angle difference is less than 4.5 for backed out terminals,improper mating,broken
% between ASP2 and APS3 for 50 counts within 50 locks, improperly formed or damaged terminals,and
Conditions for Clearing the MIL/DTC the fault. If DTC P1272 cannot be duplicated, the
D The PCM will turn the MIL “OFF” on the third information includedin the Faillure Records data
cycle during which the warm up cycles have occurred intermittently, performing the DTC
without a fault. P1272 Diagnostic Chart may isolate the cause of the
fault.
DTC P1272 – APS 2 – 3 Correlation Error

System
3 Observe the AP angle reading on the Tech 2 while Idleposition
Does the AP angle increase steadily and evenly from =86 ∼ 88 %
the closed throttle value to the wide open throttle APP sensor 3
value? =86 ∼ 88 %
Wide open
throttle APP
sensor 2 =12
∼ 14 % APP Refer to
sensor 3 =32 Diagnostic
∼ 36 % Aids Go to Step 4
circuit and the AP sensor signal circuit at the AP2
and AP3 sensor harness connector.
1. AP2 and AP3 signal circuit for a short to voltage.
2. AP2 and AP3 sensor ground circuit for high
3. AP2 and AP3 sensor ground circuit for a poor
connection.
necessary.
1. AP2 and AP3 signal circuit or 5 volge supply circuit
and AP3 sensor.
necessary.
DTC P1272 – APS 2 – 3 Correlation Error (Cont'd)

9 Replace the PCM.
Diagnostic Trouble Code (DTC) P1273 APS 1 – 3 Correlation Error
D06RY00075
throttle (WOT).
D Poor connectons.
This code detects a correlation error between D Mis routed harness.
APS1 and APS3.
D The acceleration pedal angle difference is less than 4.5 for backed out terminals, improper mating, broken
% between ASP1 and APS3 for 50 counts within 50 locks, improperly formed or damaged terminals,and
Conditions for Clearing the MIL/DTC the fault. If DTC P1273 cannot be duplicated,the
cycle during which the warm up cycles have occurred intermittently,performing the DTC
without a fault. P1273 Diagnostic Chart may isolate the cause of the
fault.
DTC P1273 – APS 1 – 3 Correlation Error

System
3 Observe the AP angle reading on the Tech2 while Idleposition
open throttle
APP sensor
1 =85 ∼ 89 % Refer to
circuit and the AP sensor signal circuit at the AP1
and AP3 sensor harness connector.
1. AP1 and AP3 signal circuit for a short to voltage.
2. AP1 and AP3 sensor ground circuit for high
3. AP1 and AP3 sensor ground circuit for a poor
connection.
necessary.
and AP3 sensor.
necessary.
DTC P1273 – APS 1 – 3 Correlation Error (Cont'd)

9 Replace the PCM.
if the latest software is released ornot.
Diagnostic Trouble Code (DTC) P1275 APS 1 Circuit Fault
D06RY00075
throttle (WOT).
D Poor connectons.
D The acceleration pedal angle is less than 2.5 % or more for backed out terminals, improper mating, broken
than 97 % for 12 counts within 500 test samples (15.6 locks, improperly formed or damaged terminals,and
m sec). poor terminal to wire connection.
D The PCM will store condition which werepresent when APP sensor 1 display on the Tech 2 while moving
the DTC was set as Freeze Frame and in the Failure connectors and wiring harnesses related to the sensor.
the fault. If DTC P1275 cannot be duplicated,the
Conditions for Clearing the MIL/DTC information included in the Faillure Records data
been run and the fault condition is no longer present. If it is determined that the DTC occurs
D A history DTC P1275 will clear after 40 consecutive trip intermittently, performing the DTC
cycle during which the warm up cycles have occurred P1275 Diagnostic Chart may isolate the cause of the
without a fault. fault.
DTC P1275 – APS 1 Circuit Fault

System
slowly opening the throttle. =12 ∼ 14 %
Does the AP angle increase steadily and evenly from Wide open Refer to
the closed throttle value to the wide open throttle throttle =86 Diagnostic
value? ∼ 88 % Aids Go to Step 4
circuit and the AP1 sensor signal circuit at the AP
1. AP1 signal circuit for a short to voltage.
2. AP1 sensor ground circuit for high resistance
between the PCM and the AP sensor.
3. AP1 sensor ground circuit for a poor connection.
necessary.
1. AP1 signal circuit or 5 volge supply circuit for a poor
connection.
2. AP1 signal circuit or 5 volge supply circuit for high
resistance between the PCM and the AP1 sensor.
necessary.
9 Replace the PCM.
D06RY00075
throttle(WOT).
D Poor connectons.
D The PCM will store condition which were present when APP sensor 2 display on the Tech 2 while moving
the fault. If DTC P1280 cannot be duplicated, the
DTC P1280 - APS 2 Circuit Fault

System
slowly opening the throttle. =86 ∼ 88
Does the AP angle increase steadily and evenly from %Wide open Refer to
necessary.
connection.
necessary.
9 Replace the PCM.
programmed.Refer to ON-Vehicle Service in Power
D06RY00075
throttle(WOT).
D Poor connectons.
high in either the circuit or the sensor.
D The PCM will store condition which were present when APP sensor 3 display on the Tech 2 while moving
DTC P1285 – APS 3 Circuit Fault

System
slowly opening the throttle. =86 ∼ 88
Does the AP angle increase steadily and evenly from %Wide open Refer to
necessary.
connection.
necessary.
9 Replace the PCM.
if the latest software is released ornot.
Diagnostic Trouble Code (DTC) P1290 ETC Forced Idle Mode
D06RY00157

D The acceleration position (AP) sensor circuit provides An intermittent may be caused by the following:
a voltage signal relative to acceleration pedal angle. D Poor connections.
The acceleration pedal angle (AP1) will vary about D Mis routed harness.
13 % at idle position to about 87 % at wide open D Rubbed through wire insulation.
throttle (WOT). D Broken wire inside the insulation.
This code detects that if the systm is in Forced Check for the following conditions:
Idle Mode. (Fail safe Mode) D Poor connection at PCM-Inspect harness connectors
Conditions for setting the DTC locks, improperly formed or damaged terminals, and
D The Ignition is “ON”.
D Forced Idle Mode is active. (Fail safe Mode) damage. If the harness appears to be OK, observe the
APP sensor 1, APP sensor 2, APP sensor 3 display on
Action Taken When the DTC Sets the Tech 2 while moving connectors and wiring
D The PCM will store condition which were present when harnesses related to the sensor.
the DTC was set as Freeze Frame and in the Failure A change in the display will indicate the location of
Records data. the fault. If DTC P1290 cannot be duplicated, the
Conditions for Clearing the MIL/DTC can be useful in determined vehicle mileage since
D The PCM will turn the MIL “OFF” on the third the DTC was last set.
consecutive trip cycle during which the diagnostic has If it is determined that the DTC occurs
been run and the fault condtion is no longer present. intermittently, performing the DTC
D A history DTC P1290 will clear after 40 cosecutive trip P1290 Diagnostic Chart may isolate the cause of the
cycle during which the warm up cycles have occurred fault.
without a fault.
feed.
DTC P1290 - ETC Forced Idle Mode

1 Was the “On - Board (OBD) System Check” Go to OBD
performed? System
3 Observe the AP angle reading on the Tech2 while Idle position
Does the AP angle increase steadily and evenly from =12 ∼ 14 %
the closed throttle value to the wide open throttle APP sensor
value? 2, 3 =86 ∼ 88
% Wide open
throttle APP
sensor 1 =86
∼ 88 % APP
sensor 2 =12
∼ 14 % APP Refer to
sensor 3 =32 Diagnostic
∼ 36 % Aids Go to Step 4
circuit and the AP1, AP2 and AP3 sensor signal
circuit at the AP sensor harness connector.
2. Observe the AP sensor reading on the Tech2.
1. AP1,AP2 and AP3 signal circuit for a short to
voltage.
2. AP1, AP2 and AP3 sensor ground circuit for high
3. AP1, AP2 and AP3 sensor ground circuit for a poor
connection.
necessary.
1. AP1, AP2 and AP3 signal circuit or 5 volge supply
circuit for a poor connection.
2. AP1, AP2 and AP3 signal circuit or 5 volge supply
circuit for high resistance between the PCM and the
AP1, AP2 and AP3 sensor.
necessary.
DTC P1290 - ETC Forced Idle Mode (Cont'd)

9 Replace the PCM.
IMPORTANT:
The replacement PCM must be programmed. Refer to
ON-Vehicle Service in Power Control Module and
the latest software is released or not.
Diagnostic Trouble Code (DTC) P1295 Power Management Mode
D06RY00088

D The throttle position (TP) sensor circuit provides a D The PCM will illuminate the malfunction indicator lamp
voltage signal relative to throttle position (blade angle). (MIL) the first time the fault is detected.
The throttle blade angle will vary about 8 % at D The PCM calculates an air flow value based on idle air
closed throttle to about 92 % at wide open throttle control valve position, throttle position, RPM and
(WOT). barometric pressure.
D The DC motor circuit provides a voltage signal relative D The PCM will store condition which were present when
to command throttle position (blade angle). the DTC was set as Freeze Frame and in the Failure
Records data.
D The mass air flow (MAF) sensor measures the amount
of air which passes through it into the engine during a Conditions for Clearing the MIL/DTC
given time. The powertrain Control Module (PCM)
uses the mass air flow information to monitor engine D The PCM will turn the MIL “OFF” on the third
operating conditions for fuel delivery calculations. consecutive trip cycle during which the diagnostic has
A large quantitiy of air entering the engine been run and the fault condtion is no longer present.
indicates an accleration or high load situation, D A history DTC P1295 will clear after 40 cosecutive trip
while a small quantity or air indicates deceleration cycle during which the warm up cycles have occurred
or idle. without a fault.
The MAF sensor produces a frequency signal Info” function or by disconnecting the PCM battery
which can be monitored using a Tech 2. The feed.
frequency will vary within a range of around 4 to
7g/s at idle to around 25 to 40g/s at maximum Diagnostic Aids
engine load.
D This DTC ditects that if the systm is in
PowerManagement Mode.(Fail safe Mode) D Poor connectons.
D The ignition is “ON”. D Broken wire inside the insulation.
D Power Management Mode is active. (Fail safe Mode) Check for the following conditions:
D Poor connection at PCM-Inspect harness connectors
locks, improperly formed or damaged terminals,and information included in the Faillure Records data
poor terminal to wire connection. can be useful in determined vehicle mileage since
D Damaged harness-Inspect the wiring harness for the DTC was last set.
damage. If the harness appears to be OK, observe the If it is determined that the DTC occurs
TP sensor 1, TP sensor 2 display on the Tech 2 while
moving connectors and wiring harnesses related to the intermittently, performing the DTC
sensor. P1295 Diagnostic Chart may isolate the cause of the
A change in the display will indicate the location of fault.
the fault.If DTC P1295 cannot be duplicated, the
DTC P1295 - Power Management Mode

System
4 Observe the TP angle reading on the Tech 2 while Closed
slowly opening the throttle. throttle TP
Does the TP angle increase steadily and evenly from sensor 1 =8 ∼
the closed throttle value to the wide open throttle 10 % TP
value? sensor 2 =90
∼ 99 % Wide
open throttle
TP sensor 1
=90 ∼ 92 %
TP sensor 2
=8 ∼ 10 % Go to Step 9 Go to Step 5
2. Disconnect the DC motor.
Is the DC motor reading near the specified value? 0.3 ∼ 100 W Go to Step 6 Go to Step 8
6 Check the DC motor harness between the PCM and
DC Motor circuit at the DC motor harness connector.
7 Check the throttle valve assembly.
Was a problem found? Verify repair Go to Step 8
8 Replace the DC motor. (Replace the Throttle valve
assembly)
DTC P1295 - Power Management Mode (Cont'd)

“A”circuit and the TP1 and TP2 sensor signal circuit
at the TP sensor harness connector.
1. TP1 and TP2 signal circuit for a short to voltage.
2. TP1 and TP2 sensor ground circuit for high
3. TP1and TP2 sensor ground circuit for a poor
connection.
necessary.
1. TP1and TP2 signal circuit or 5 volt reference circuit
2. TP1 and TP2 signal circuit or 5 volt reference circuit
for high resistance between the PCM and the
TP1and TP2 sensor.
necessary.
Is the “MAF Frequency” below the specified value? 6 ∼ 10 g/s Go to Step 15 Go to Step 18
motors).
routing.
18 1. With the engine idling, monitor “MAF Frequency.”
Does the Tech 2 indicate a “MAF Frequency” at
thespecified value? 6 ∼ 10 g/s Go to Step 16 Go to Step 19
DTC P1295 - Power Management Mode (Cont'd)

19 1. Ignition “ON”,engine not running.
start with diagnosis chart forother sensors in the circuit
MAP grund circuit.
as necessary.
23 Replace the PCM.
IMPORTANT:
And also refer to latest Service Bulletin.Check to see if
Diagnostic Trouble Code (DTC) P1299 ETC Forced Engine Shutdown Mode
D06RY00090

D The throttle position (TP) sensor circuit provides a D The PCM will store condition which were present when
voltage signal relative to throttle position (blade angle). the DTC was set as Freeze Frame and in the Failure
Records data.
The throttle blade angle will vary about 8% at
closed throttle to about 92% at wide open Conditions for Clearing the MIL/DTC
throttle(WOT). D The PCM will turn the MIL “OFF” on the third
D The DC motor circuit provides a voltage signal relative consecutive trip cycle during which the diagnostic has
to command throttle position (blade angle). been run and the fault condtion is no longer present.
D The mass air flow (MAF) sensor measures the amount D A history DTC P1299 will clear after 40 cosecutive trip
of air which passes through it into the engine during a cycle during which the warm up cycles have occurred
given time. The powertrain Control Module (PCM) without a fault.
uses the mass air flow information to monitor engine D DTC P1299 can be cleared using the Tech 2 “Clear
operating conditions for fuel delivery calculations. A Info” function or by disconnecting the PCM battery
laege quantitiy of air entering the engine indicates an feed.
accleration or high load situation, while a small quantity
or air indicates deceleration or idle. Diagnostic Aids
The MAF sensor produces a frequency signal An intermittent may be caused by the following:
which can be monitored using a Tech 2. The D Poor connections.
frequency will vary within a range of around 4 to
7g/s at idle to around 25 to 40g/s at maximum D Mis routed harness.
engine load. D Rubbed through wire insulation.
D This DTC ditects if the system is in ECT Forced Engine D Broken wire inside the insulation.
Shutdown Mode.(Fail safe Mode) Check for the following conditions:
Conditions for setting the DTC for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals,and
D The ignition is “ON”. poor terminal to wire connection.
D ECT Forced Engine Shutdown Mode is active. (Fail D Damaged harness-Inspect the wiring harness for
safe Mode) damage. If the harness appears to be OK, observe the
TP sensor 1, TP sensor 2 display on the Tech 2 while
A change in the display will indicate the location of Diagnostic Chart may isolate the cause of the
the fault. If DTC P1299 cannot be duplicated, the fault.
DTC P1299 - ETC Forced Engine Shutdown Mode

System
value? sensor 2 =90
∼ 92 % Wide
open throttle
TP sensor 1
=90 ∼ 92 %
TP sensor 2
Is the DC motor reading near the specified value? 0.3 ∼ 100W Go to Step 5 Go to Step 7
6 Check the throttle valve assembly.
Was a problem found? Verify repair Go to Step 7
7 Replace the DC motor. (Replace the Throttle valve
assembly)
circuit and the TP1 and TP2 sensor signal circuit at
the TP sensor harness connector.
2. .Observe the TP sensor reading on the Tech 2.
DTC P1299 - ETC Forced Engine Shutdown Mode (Cont'd)

connection.
necessary.
TP1and TP2 sensor.
necessary.
motors).
routing.
specified value? 6 ∼ 10 g/s Go to Step 15 Go to Step 18
18 1. Ignition “ON”,engine not running.
DTC P1299 - ETC Forced Engine Shutdown Mode (Cont'd)

2. Connect a test 5 volt reference “A” circuit and the
MAP signal at the MAP sensor harness connector.
Is the MAP reading less than the specified value?(If no,
and see if 5Vreturns.) — Go to Step 21 Go to Step 20
MAP ground circuit.
2. If the MAP signal circuit is open or shorted ,repair it
as necessary.
22 Replace the PCM.
programmed.
Diagnostic Trouble Code (DTC) P1310 ION Sensing Module Diagnosis
D06RY00067
Circuit Description D MAP sensor signal is between 26kPa and 100 kPa.
The Power Control Module (PCM) checks the validity of D Fuel level is more than 10%.
the signals used in the ION Sensing module at the D Engine speed is between 650rpm and 6500rpm.
following engine operating conditions. D No Crank DTCs set.
D The Deceleration Fuel Cut Off (DFCO) test is D No System voltage DTCs set.
performed to evaluate the Combustion Quality (CQ)
signal pulse width if it is below a predetermined value, Action Taken When the DTC Sets
the value it is expected to be during DFCO conditions.
If the CQ signal pilse width is above the predetermined D The PCM will illuminate the malfunction indicator lamp
threshold, the fail counter will be incremented. If the (MIL) the first time the fault is detected.
failure counter exceeds the calibration, then the test is D The PCM calculates an air flow value based on idle air
conplete and a failure will be reported. control valve position, throttle position, RPM and
D The Power Enrichment (PE) test is performed to barometric pressure.
evaluate the Combustion Quality (CQ) signal pulse D The PCM will store condition which were present when
width if it is below a predetermined value, the value it the DTC was set as Freeze Frame and in the Failure
is expected to be during PE conditions. Records data.
If the CQ signal pulse width is above the
predetermined threshold, the fail counter will be Conditions for Clearing the MIL/DTC
incremented. If the failure counter exceeds the D The PCM will turn the MIL “OFF” on the third
calibration, then the test is complete and a failure consecutive trip cycle during which the diagnostic has
will be reported. been run and the fault condtion is no longer present.
D The Combustion Quality (CQ) test is performed to D A history DTC P1310 will clear after 40 cosecutive trip
check if inappropriate (CQ) signal status were cycle during which the warm up cycles have occurred
detected. If missing CQ pulses or multiple CQ pulses without a fault.
or CQ pulse width calculation errors were detected, the D DTC P1310 can be cleared using the Tech 2 “Clear
fail counter will be incremented. If the failure counter Info” function or by disconnecting the PCM battery
exceeds the calibration, then the test is complete and feed.
a failure will be reported.
Diagnostic Aids
Conditions for setting the DTC An intermittent may be caused by the following:
D Ignition voltage is between 10volt and 16 volts. D Poor connections.
moving connectors and wiring harnesses related to the
sensor.
information included in the Failure Records data
fault.
DTC P1310 - ION Sensing Module Diagnostic

System
2. Disconnect the ION Sensing module.
Is the action complete? — Go to Step 4 Go to Step 3
4 Check the ION Sensing harness between the PCM and
ION Sensing module circuit harness connector.
6 Check the ION Sensing harness between the ignition
coil and ION Sensing module circuit at the ION Sensing
Module harness connector.
necessary.
1. ION Sensing module ground circuit for a poor
connection.
necessary.
DTC P1310 - ION Sensing Module Diagnostic (Cont'd)

11 Replace the PCM.
programmed.

P1311 ION Sensing Module SEC line 1 Circuit Fault
D06RY00067

D The Power Control Module (PCM) will compara the D The PCM will illuminate the malfunction indicator lamp
secondary current reading to a predetermined (MIL) the first time the fault is detected.
maximum and minimum thresholds. D The PCM calculates an air flow value based on idle air
If the secondary current signal pulse width is out control valve position, throttle position, RPM and
of the predetermined renge, the fail counter will be barometric pressure.
incremented. If the failure counter exceeds the D The PCM will store condition which were present when
calibration, then the PCM is complete and a failure the DTC was set as Freeze Frame and in the Failure
will be reported. If the sample counter threshold is Records data.
reached before the failure threshold, then the
PCM is complete and pass will be reported. Conditions for Clearing the MIL/DTC
This PCM will detect an open/short circuit in the D The PCM will turn the MIL “OFF” on the third
secondary current sense input circuit, misfire on consecutive trip cycle during which the diagnostic has
the entire bank for the secondary current sense been run and the fault condition is no longer present.
input circuit, coil failure, and same internal Ignition D A history DTC P1311 will clear after 40 cosecutive trip
Current Sense System (ICSS) module faults. cycle during which the warm up cycles have occurred
without a fault.
D Ignition voltage is between 10volt and 16 volts. feed.
D MAP sensor signal is between 26kPa and 100 kPa.
D Fuel level is more than 10%. Diagnostic Aids
D Engine speed is between 650rpm and 6500rpm. An intermittent may be caused by the following:
D ION Sensing Module circuit is open or shorted signals D Poor connections.
on the SEC 1 line. D Mis routed harness.
D Poor connection at PCM-Inspect harness connectors D A change in the display will indicate the location of the
for backed out terminals, improper mating, broken fault. If DTC P1311 cannot be duplicated, the
locks, improperly formed or damaged terminals, and information included in the Failure Records data can be
poor terminal to wire connection. useful in determined vehicle mileage since the DTC
D Damaged harness-Inspect the wiring harness for was last set.
damage. If the harness appears to be OK, observe the D If it is determined that the DTC occurs intermittently,
moving connectors and wiring harnesses related to the performing the DTC P1311 Diagnostic Chart may
sensor. isolate the cause of the fault.
DTC P1311 - ION Sensing Module SEC line 1 Circuit Fault

System
4 Check the ION Sensing module harness between the
PCM and ION Sensing module circuit at the ION
Sensing module harness connector.
ignition coil and ION Sensing module circuit at the SEC
line 1 harness connector.
necessary.
connection.
necessary.
DTC P1311 - ION Sensing Module SEC line 1 Circuit Fault (Cont'd)
11 Replace the PCM.
programmed.

P1312 ION Sensing Module SEC line 2 Circuit Fault
D06RY00067

D The Power Control Module (PCM) will compara the D The PCM will illuminate the malfunction indicator lamp
secondary current reading to a predetermined (MIL) the first time the fault is detected.
maximum and minimum thresholds. D The PCM calculates an air flow value based on idle air
If the secondary current signal pulse width is out control valve position, throttle position, RPM and
of the predetermined renge, the fail counter will be barometric pressure.
incremented. If the failure counter exceeds the D The PCM will store condition which were present when
calibration, then the PCM is complete and a failure the DTC was set as Freeze Frame and in the Failure
will be reported. If the sample counter threshold is Records data.
reached before the failure threshold, then the
PCM is complete and pass will be reported. Conditions for Clearing the MIL/DTC
This PCM will detect an open/short circuit in the D The PCM will turn the MIL “OFF” on the third
secondary current sense input circuit, misfire on consecutive trip cycle during which the diagnostic has
the entire bank for the secondary current sense been run and the fault condition is no longer present.
input circuit, coil failure, and same internal Ignition D A history DTC P1312 will clear after 40 cosecutive trip
Current Sense System (ICSS) module faults. cycle during which the warm up cycles have occurred
without a fault.
D Ignition voltage is between 10volt and 16 volts. feed.
D MAP sensor signal is between 26kPa and 100 kPa.
D Fuel level is more than 10%. Diagnostic Aids
D Engine speed is between 650rpm and 6500rpm. An intermittent may be caused by the following:
D ION Sensing Module circuit is open or shorted signals D Poor connections.
on the SEC 2 line. D Mis routed harness.
D Poor connection at PCM-Inspect harness connectors information included in the Failure Records data
for backed out terminals, improper mating, broken can be useful in determined vehicle mileage since
locks, improperly formed or damaged terminals, and the DTC was last set.
damage. If the harness appears to be OK, observe the intermittently, performing the DTC P1312
moving connectors and wiring harnesses related to the Diagnostic Chart may isolate the cause of the
sensor. fault.
DTC P1312 - ION Sensing Module SEC line 2 Circuit Fault

System
PCM and ICSS module circuit at the ION Sensing
ignition coil and ION Sensing module circuit at the SEC
line 2 harness connector.
necessary.
connection.
necessary.
DTC P1312 - ION Sensing Module SEC line 2 Circuit Fault (Cont'd)
11 Replace the PCM.
programmed.

P1326 ION Sensing Module Combustion Quality Input Circuit Fault
D06RY00067

The Power Control Module (PCM) checks the validity of D The PCM will turn the MIL “OFF” on the third
the signals used in the ION Sensing module at the consecutive trip cycle during which the diagnostic has
following engine operating conditions. been run and the fault condition is no longer present.
D The test is performed to evauate the Combustion D A history DTC P1326 will clear after 40 cosecutive trip
Quality (CQ) signal pulse width if it is within a cycle during which the warm up cycles have occurred
predetermined range. If the CQ signal puls width is out without a fault.
of the predetermined range, the fail counter will be D DTC P1326 can be cleared using the Tech 2 “Clear
incremented. If the failure counter exceeds the Info” function or by disconnecting the PCM battery
calibration, then test is complete and a failure will be feed.
reported. If the sample counter threshold is reached
before the failure threshold, then the test is complete Diagnostic Aids
and a pass will be reported. This test will detect an
open/short in the QC line circuit, ION Sensing module An intermittent may be caused by the following:
faults and analog input faults in the PCM. D Poor connections.
D Ignition voltage is between 10volt and 16 volts. D Broken wire inside the insulation.
D No Cramk DTCs set. Check for the following conditions:
D No cylinder ID DTCs set. D Poor connection at PCM-Inspect harness connectors
Action Taken When the DTC Sets locks, improperly formed or damaged terminals, and
(MIL) the first time the fault is detected. D Damaged harness-Inspect the wiring harness for
D The PCM calculates an air flow value based on idle air moving connectors and wiring harnesses related to the
control valve position, throttle position, RPM and sensor.
D The PCM will store condition which were present when the fault. If DTC P1326 cannot be duplicated, the
Records data. information included in the Failure Records data
can be useful in determined vehicle mileage since Diagnostic Chart may isolate the cause of the
the DTC was last set. fault.
DTC P1326 - ION Sensing Module Combustion

System
4. Using a Tech 2, monitor “DTC”info for DTC P1326. Refer to
PCM and ION Sensing module circuit at the QC line
harness connector.
ignition coil and ICSS module circuit at the ION Sensing
necessary.
connection.
necessary.
DTC P1326 - ION Sensing Module Combustion (Cont'd)

11 Replace the PCM.
programmed.
And also refer to latest Service Bulletin .Check to see

P1340 ION Sensing Module Cylinder ID Fault (Cylinder Synchronization Fail)
D06RY00067
The Power Control Module (PCM) checks the validity of Records data.
the signals used in the ION Sensing module at the
following engine opreating conditions. Conditions for Clearing the MIL/DTC
D This test will return a fault if the cylinder
synchronization routine has not been completed after D The PCM will turn the MIL “OFF” on the third
a predetermined number of events after crank. This consecutive trip cycle during which the diagnostic has
test will detect fault that will prevent the PCM from been run and the fault condtion is no longer present.
synchronaization, such as Knock Signal (KI) - D A history DTC P1340 will clear after 40 cosecutive trip
Combustion Quality (CQ) lines being swapped, cycle during which the warm up cycles have occurred
shorted spark plugs, ION Sensing module faults, an without a fault.
PCM hardware faults. D DTC P1340 can be cleared using the Tech 2 “Clear
Conditions for setting the DTC feed.
D Ignition voltage is between 11volt and 16 volts.
Diagnostic Aids
D Engine speed is between 650rpm and 6500rpm.
D No ECT DTCs set.
D Poor connectons.
D No injector DTCs set.
D No Fuel Trim DTCs set.
D No Misfire DTCs set.
D No system voltage DTCs set.
Action Taken When the DTC Sets D Poor connection at PCM-Inspect harness connectors
D The PCM will illuminate the malfunction indicator lamp locks, improperly formed or damaged terminals,and
(MIL) the first time the fault is detected. poor terminal to wire connection.
D The PCM calculates an air flow value based on idle air D Damaged harness–Inspect the wiring harness for
control valve position, throttle position, RPM and damage. If the harness appears to be OK, observe the
barometric pressure. moving connectors and wiring harnesses related to the
sensor.
the fault. If DTC P1340 cannot be duplicated, the intermittently, performing the DTC P1340
information included in the Faillure Records data Diagnostic Chart may isolate the cause of the
can be useful in determined vehicle mileage since fault.
DTC P1340 - ION Sensing Module Cylinder ID Fault

(Cylinder Synchronization Fail)
System
4. Using a Tech 2, monitor “ DTC” info for DTC P1340. Refer to
Does the Tech 2 indicate DTC P1340 failed DiagnosticAid
thisignition? — Go to Step 3 s
PCM and ICSS module circuit at the QC line harness
connector.
ignition coil and ION Sensing module circuit at the ION
Sensing Module harness connector.
necessary.
connection.
necessary.
DTC P1340 - ION Sensing Module Cylinder ID Fault

(Cylinder Synchronization Fail) (Cont'd)
11 Replace the PCM.
IMPORTANT: IMPORTANT;
Diagnostic Trouble Code (DTC) P1404 EGR Stuck Closed
D06RY00178

responds properly to commands from the PCM, and to been run and the fault condition is no longer present.
detect a fault if current pintle zero position is different from D A history DTC P1404 will clear after 40 consecutive
the learned zero position. If the PCM detects a pintle warm-up cycles have occurred without a fault.
position signal indicates more than 30 % different D DTC P1404 can be cleared by using the Tech 2 “Clear
between current zero position and the learned zero Info” function or by disconnecting the PCM battery
position for more than 5 seconds, and this condition exists feed.
3 times during trip, then the PCM will set DTC P1404.
Diagnostic Aids
D Ignition voltage is between 11 and 16 volts. D Excessive carbon deposit on EGR valve shaft and/or
foreign material may cause the EGR valve not to fully
D Intake Air temp is more than 3°C. seated. The carbon deposit may occur by unusual port
D Desired EGR position is 0. operation. Remove foreign material and/or excessive
D Difference of EGR pintle position between current and carbon deposit on EGR valve shaft and may allow the
the learned zero is more than 30 % for more than 5 EGR valve to be fully seated.
seconds, and exists three time to the above condition D Poor connection or damaged harness – Inspect the
during a trip the PCM will set DTC 1404. Then it trigger wiring harness for damage.
the PCM lights on. Reviewing the Failure Records vehicle mileage since the
Action Taken When the DTC Sets the condition that caused the DTC to be set occurs. This
D The PCM will illuminate the malfunction indicator lamp may assist in diagnosing the condition.
(MIL) after consecutive 2nd trip in which the fault is
detected.
when the DTC was set as Freeze Frame and in Failure
Records data.
DTC P1404 – EGR Stuck Closed

performed? System
3. Using a Tech 2, monitor “DTC inf. for DTC P1404
pin or terminals.
2. Inspect EGR valve for any excessive carbon
deposit on EGR shaft.
3. Inspect for any foreign material inside of EGR valve.
Was excessive carbon deposit on EGR valve shaft
and/or foreign material in EGR valve ? — Go to Step 6 Go to Step 7
6 1. Clean up EGR valve shaft and inside of EGR valve.
2. Remove foreign material from EGR valve.
3. Visually inspect damage of pintle and seat to see if it
is bent. If damaged leakage may occur. Verify repair
7 1. Install the EGR valve.
5. On the Tech 2, select EGR Control Test.
40%.
8 1. Reset the learned zero EGR valve position.
2. Repeat step 7.
Did EGR work properly? — Verify repair Go to Step 9
DTC P1404 – EGR Stuck Closed (Cont'd)

10 Replace the PCM.
procedures.
Diagnostic Trouble Code (DTC) P1441 EVAP System Flow During Non-Purge
D06RY00128
Circuit Description D Start-up intake air temperature (IAT) and start-up

engine coolant temperature (ECT) are both above 5°C
Canister purge is controlled by a solenoid valve that (41°F).
allows manifold vacuum to purge the canister. The
D The difference between start-up ECT and start-up IAT
powertrain control module (PCM) supplies a ground to is less than 25°C (45°F).
energize the solenoid valve (purge “ON”). The EVAP
D TP sensor indicates a throttle position above 12%.
purge solenoid control is pulse-width modulated (PWM)
or turned “ON” and “OFF” several times a second. The D Battery voltage is between 11.5 volts and 16 volts.
duty cycle (pulse width) is determined by engine D Engine speed is between 800 and 6,000 RPM.
operating conditions including load, throttle position, D Canister purge duty cycle is below 3%.
coolant temperature and ambient temperature. The duty D Canister purge vacuum switch is open, which results
cycle is calculated by the PCM and the output is in the PCM signal voltage (from the vacuum switch
commanded when the appropriate conditions have been input) being approximately 12 volts.
met. D All conditions are present for at least 3 seconds.
The EVAP purge vacuum switch is a normally closed
switch positioned in the purge line between the canister Action Taken When the DTC Sets
and to EVAP purge solenoid. The EVAP purge vacuum D The PCM will illuminate the malfunction indicator lamp
switch will open when vacuum increases to greater than 5 (MIL) after the second consecutive trip in which the
inches of water in the purge line. The PCM monitors the fault is detected.
EVAP purge vacuum switch signal to determine if the D The PCM will store conditions which were present
evaporative emission control system is working properly. when the DTC was set as Freeze Frame and in the
If the switch is open (purge flow detected) when the PCM Failure Records data.
is not commanding the EVAP purge solenoid “ON,” DTC
P1441 will be set.
Conditions for Setting the DTC consecutive trip cycle during which the diagnostic has
D No active ECT sensor, IAT sensor, MAP sensor,
vacuum switch, or TP sensor DTCs set. D A history DTC P1441 will clear after 40 consecutive
warm–up cycles have occurred without a fault.
D BARO reading is above 85 kPa.
D Engine coolant temperature is below 70°C (158°F).
Diagnostic Chart.
Diagnostic Aids 2. The canister purge vacuum switch is normally closed
Check for the following conditions: when no vacuum (purge) is present. With the
ignition “ON” and the engine “OFF,” there shouldn’t
for backed-out terminals, improper mating, broken be any vacuum (purge) present in the EVAP
locks, improperly formed or damaged terminals, and system.
poor terminal-to-wire connection. 3. Determines if the PCM is able to control the EVAP
D Damaged harness – Inspect the wring harness for purge solenoid valve.
damage. If the harness appears to be OK, observe the 4. Determines if the DTC will set under the conditions
EVAP vacuum switch display on the Tech 2 while present when the DTC was originally stored. If not,
moving connectors and wiring harnesses related to the
sensor. A change in the display will indicate the the fault is intermittent.
location of the fault. 5. Checks for a grounded EVAP purge solenoid driver
Reviewing the Failure Records vehicle mileage since the circuit, a faulty EVAP vacuum switch, or a leaking
diagnostic test last failed may help determine how often EVAP purge solenoid valve.
DTC P1441 – EVAP System Flow During Non-Purge

performed? System
2. Remove the fuel filler cap.
Go to DTC
4. Observe “Fuel Tank Pressure” on the Tech 2. P0452 or
Is “Fuel Tank Pressure” at the specified value? 1.51V Go to Step 3 P0453
3 1. Re-install the fuel filler cap.
2. Using the Tech 2, command the EVAP Vent
Solenoid Valve “ON” (Closed).
3. Disconnect the canister side rubber hose end that
hose is connected between the Purge Solenoid
Valve and Canister.
IMPORTANT: Before continuing with the diagnosis,
zero the EVAP pressure/purge cart J41413 (refer to the
tool operating instructions).
And them monitor the fuel tank inner pressure using the
Tech 2.
Does the fuel tank pressure remain the specified
value? 1.52 - 1.60V Go to Step 4 Go to Step 6
4 1. Disconnect the EVAP pressure/purge cart J41413,
and then plug the hose end.
2. Disconnect the rubber hose end of engine vacuum
source side, (the hose connected between Purge
Solenoid Valve and engine).
3. Connect the vacuum hand pump to this rubber hose
end.
4. Then apply the -15 in H2O vacuum by the vacuum
pump.
5. Monitor the fuel tank inner pressure using the Tech
2.
Does the fuel tank inner pressure hold the specified
value? 1.47 - 1.51V Go to Step 6 Go to Step 5
DTC P1441 – EVAP System Flow During Non-Purge (Cont'd)

5 Replace the Purge Solenoid Valve.
— Verify Repair —
6 1. Check leaks, kinks or pinched hoses at the EVAP
system rubber hose line, and also check if the
rubber hoses are correctly connected or not.
2. Check for a leak from Vent Solenoid Valve and
EVAP system rubber hoses, and also check for
clogged Filter of air separator which is located near
the vent solenoid valve.
Was a problem found? Using the Vacuum Hose
Routing Diagram, repair or re-connect the rubber
hoses correctly. — Verify Repair Go to Step 7
7 1. Start engine.
2. Remove the Fuel Filler cap.
3. Using the Tech 2, command the EVAP Vent
Solenoid Valve “ON” (closed) and Purge Solenoid
Valve “OFF” (0%).
4. Replace the Fuel Filler Cap.
5. Run the engine at 2500RPM constant while
monitoring “Fuel Tank Vacuum” on the Tech 2.
Does the fuel tank vacuum remain at the specified Go to
value while the EVAP Vent Solenoid Valve “ON” Diagnostic
(closed) and Purge Solenoid Valve “OFF” (0%)? 30 - 40 % Verify Repair Aids
Diagnostic Trouble Code (DTC) P1514 TPS - MAF Correlation Error
D06RY00090

D The throttle position (TP) sensor circuit provides a D The PCM will illuminate the malfunction indicator lamp
voltage signal relative to throttle blade angle. (MIL) the first time the fault is detected.
The throttle blade angle will vary about 8 % at D The PCM calculates an air flow value based on idle air
closed throttle to about 92 % at wide open throttle control valve position, throttle position, RPM and
(WOT). barometric pressure.
D The mass air flow (MAF) sensor measures the amount D The PCM will store condition which were present when
of air which passes through it into the engine during a the DTC was set as Freeze Frame and in the Failure
given time. The powertrain Control Module (PCM) Records data.
uses the mass air flow information to monitor engine
operating conditions for fuel delivery calculations. Conditions for Clearing the MIL/DTC
A large quantitiy of air entering the engine D The PCM will turn the MIL “OFF” on the third
indicates an accleration or high load situation, consecutive trip cycle during which the diagnostic has
while a small quantity or air indicates deceleration been run and the fault condtion is no longer present.
or idle. D A history DTC P1514 will clear after 40 cosecutive trip
The MAF sensor produces a frequency signal without a fault.
which can be monitored using a Tech 2. The
frequency will vary within a range of around 4 to D DTC P1514 can be cleared using the Tech 2 “Clear
7g/s at idle to around 25 to 40g/s at maximum feed.
engine load.
Diagnostic Aids
D The engine is running. D Poor connectons.
D No MAF sensor DTCs are set. D Mis routed harness.
D Throttle actuation mode is not off. D Rubbed through wire insulation.
D MAF reading-ETC estimated air flow is less than 40g/s D Broken wire inside the insulation.
for 250 failres within test 1000 test samples (15.6 m
sec). Check for the following conditions:
D Poor connection at PCM - Inspect harness connectors
for backed out terminals, improper mating,broken
locks, improperly formed or damaged terminals,and greater at the time of the 1 – 2 shift. If not, check for a
poor terminal to wire connection. restriction.
D Damaged harness - Inspect the wiring harness for A change in the display will indicate the location of
damage. If the harness appears to be OK, observe the the fault. If DTC P1514 cannot be duplicated, the
Mass Air Flow, TP sensor 1, TP sensor 2 display on the information included in the Faillure Records data
Tech 2 while moving connectors and wiring harnesses can be useful in determined vehicle mileage since
related to the sensor. the DTC was last set.
D Plugged intake air duct or filter element
D A wide - open throttle acceleration from a stop should intermittently, performing the DTC P1514
cause the mass air flow displayed on a Tech 2 to
increase from about 3 – 6 g/s at idle to 100 g/s or Diagnostic Chart may isolate the cause of the
fault.
DTC P1514 - TPS-MAF Correlation Error

System
motors).
routing.
Does the Tech 2 indicate a “MAF Frequency” at
thespecified value? 6 ∼ 10 g/s Go to Step 6 Go to Step 9
DTC P1514 - TPS-MAF Correlation Error (Cont'd)

9 1. Ignition“ON”, engine not running.
and see if 5Vreturns.) — Go to Step 12 Go to Step 11
MAP ground circuit.
as necessary.
value? sensor 2 =90
∼ 92 % Wide
open throttle
TP sensor 1
=90 ∼ 92 % Refer to
TP sensor 2 Diagnostic
3. TP1 and TP2 sensor ground circuit for a poor
connection.
necessary.
DTC P1514 - TPS-MAF Correlation Error (Cont'd)

TP1and TP2 sensor.
necessary.
19 Replace the PCM.
IMPORTANT:

P1515 Command - Actual TPS Correlation Error
D06RY00088
Circuit Description D The PCM calculates an air flow value based on idle air
control valve position, throttle position, RPM and
D The throttle position (TP) sensor circuit provides a barometric pressure.
voltage signal relative to throttle position (blade angle).
The throttle blade angle will vary about 8 % at the DTC was set as Freeze Frame and in the Failure
closed throttle to about 92 % at wide open Records data.
throttle(WOT).
D The DC motor circuit provides a voltage signal relative Conditions for Clearing the MIL/DTC
to command throttle position (blade angle). D The PCM will turn the MIL “OFF” on the third
D This DTC ditects the difference between actual throttle consecutive trip cycle during which the diagnostic has
position and command throttle position. been run and the fault condtion is no longer present.
Conditions for setting the DTC cycle during which the warm up cycles have occurred
D The ignition is “ON”. without a fault.
D Throttle actuation mode is normal. D DTC P1515 can be cleared using the Tech 2 “Clear
D Command Throttle position - Actual Throttle position is feed.
more than + 5 % for 100 counts within test 1000 test
samples (15.6 m sec) else Actual Throttle position is Diagnostic Aids
less than + 40 % and Command Throttle position -
Actual Throttle position is more than - 5 % or Command An intermittent may be caused by the following:
Throttle position - Actual Throttle position is more than D Poor connectons.
- 20 % for 150 failres within test 1000 test samples D Mis routed harness.
(15.6 m sec).
Action Taken When the DTC Sets D Broken wire inside the insulation.
(MIL) the first time the fault is detected. D Poor connection at PCM-Inspect harness connectors
for backed out terminals, mproper mating, locks,
terminal to wire connection.
D Damaged harness-Inspect the wiring harness for can be useful in determined vehicle mileage since
damage. If the harness appears to be OK, observe the the DTC was last set.
TP sensor 1, TP sensor 2 display on the Tech2 while
fault.
DTC P1515 - Command - Actual TPS Correlation Error

System
4. Using a Tech 2, monitor “ DTC” info for DTC P1515. Refer to
Does the Tech 2 indicate DTC P1515 failed Diagnostic
thisignition? — Go to Step 4 Aids
value? sensor 2 =90
∼ 92 % Wide
open throttle
TP sensor 1
=90 ∼ 92 %
TP sensor 2
7 Replace the DC motor.
DTC P1515 - Command - Actual TPS Correlation Error (Cont'd)

connection.
necessary.
TP1and TP2 sensor.
necessary.
13 Replace the PCM.
IMPORTANT:

P1516 Command - Actual TPS Correlation Error
D06RY00088

D The throttle position (TP) sensor circuit provides a D The PCM will turn the MIL “OFF” on the third
voltage signal relative to throttle position (blade angle). consecutive trip cycle during which the diagnostic has
The throttle blade angle will vary about 8 % at closed been run and the fault condtion is no longer present.
throttle to about 92 % at wide open throttle (WOT). D A history DTC P1516 will clear after 40 cosecutive trip
D The DC motor circuit provides a voltage signal relative cycle during which the warm up cycles have occurred
to command throttle position (blade angle). without a fault.
D This DTC detects the dufference between actual D DTC P1516 can be cleared using the Tech 2 “Clear
throttle position and command throttle position in Info” function or by disconnecting the PCM battery
steady state. feed.
Conditions for setting the DTC Diagnostic Aids

D The ignition is “ON”. An intermittent may be caused by the following:
D Throttle Actuation mode is normal. D Poor connectons.
D Command Throttle position-Actual Throttle positionis D Mis routed harness.
less than 8 % when desird TPS is sutudy wihtin 0.5 D Rubbed through wire insulation.
%for 30 second within test samples (30 second) D Broken wire inside the insulation.
D The PCM will illuminate the malfunction indicator lamp for backed out terminals, improper mating, broken
(MIL) the first time the fault is detected. locks, improperly formed or damaged terminals, and
D The PCM calculates an air flow value based on idle air poor terminal to wire connection.
control valve position, throttle position, RPM and D Damaged harness - Inspect the wiring harness for
barometric pressure. damage. If the harness appears to be OK, observe the
D The PCM will store condition which were present when TP sensor 1, TP sensor 2 display on the Tech2 while
the DTC was set as Freeze Frame and in the Failure moving connectors and wiring harnesses related to the
Records data. sensor.
the fault. If DTC P1516 cannot be duplicated, the intermittently, performing the DTC P1516
information included in the Faillure Records data Diagnostic Chart may isolate the cause of the
can be useful in determined vehicle mileage since fault.
DTC P1516 - Command - Actual TPS Correlation Error

System
value? sensor 2 =90
∼ 92 % Wide
open throttle
TP sensor 1
=90 ∼ 92 %
TP sensor 2
DTC P1516 - Command - Actual TPS Correlation Error (Cont'd)

connection.
necessary.
for high resistance between the PCM and the TP1
and TP2 sensor.
necessary.
13 Replace the PCM.
IMPORTANT:
Diagnostic Trouble Code (DTC) P1523 Actuator Control Return Performance
D06RY00088
D The throttle position (TP) sensor circuit provides a feed.
voltage signal relative to throttle position (blade angle).
The throttle blade angle will vary about 8 % at Diagnostic Aids
closed throttle to about 92 % at wide open An intermittent may be caused by the following:
throttle(WOT).
D Poor connectons.
D The DC motor circuit provides a voltage signal relative D Mis routed harness.
to command throttle position (blade angle).
D This DTC ditects if the throttle return to the default
position at key on, steady state. D Broken wire inside the insulation.
Conditions for setting the DTC D Poor connection at PCM-Inspect harness connectors
D The ignition is “ON”. locks, improperly formed or damaged terminals, and
D Normalized TPS is less than 0 % but Normalized TPS poor terminal to wire connection.
is more than 25 %. D Damaged harness-Inspect the wiring harness for
Action Taken When the DTC Sets TP sensor 1, TP sensor 2 display on the Tech 2 while
D The PCM will store condition which were present when moving connectors and wiring harnesses related to the
the DTC was set as Freeze Frame and in the Failure sensor.
been run and the fault condtion is no longer present. If it is determined that the DTC occurs
D A history DTC P1523 will clear after 40 cosecutive trip intermittently, performing the DTC P1523
cycle during which the warm up cycles have occurred Diagnostic Chart may isolate the cause of the
DTC P1523 - Actuator Control Return Performance

System
value? sensor 2 =90
∼ 92 % Wide
open throttle
TP sensor 1
=90 ∼ 92 %
TP sensor 2
connection.
necessary.
DTC P1523 - Actuator Control Return Performance (Cont'd)

TP1and TP2 sensor.
necessary. Go to Step 12
Was a problem found? — Verify repair
12 Replace the PCM.
IMPORTANT:
Diagnostic Trouble Code (DTC) P1625 PCM Unexpected Reset

The powertrain control module (PCM) monitors D The PCM will turn the MIL “OFF” on the third
unexpected PCM reset. This will not turn on MIL light on, consecutive trip cycle during which the diagnostic has
only records code DTC P1625. been run and the fault condition is no longer present.
D Clock or COP (Computer Operating Properly) reset. D DTC P1625 can be cleared by using the Tech 2 “Clear
Action Taken When the DTC Sets feed.
D The PCM will not illuminate the malfunction indicator Diagnostic Aids
lamp (MIL).
when the DTC was set as Failure Records only. This D P1625 alone stored does not need diagnosis. Clear
information will not be stored as Freeze Frame data. DTC code.
DTC P1625 – PCM Unexpected Reset

performed? System
2 1. Ignition is “ON”.
3. Start the engine at let it Idle.
Go to
4. On the Tech 2, select “DTC info”. Diagnostic
3 1. Ignition is “ON”.
2. Clear DTC P1625 by using the Tech 2 “Clear Info”.
3. Start the engine at let it Idle.
Go to
4. On the Tech 2, select “DTC info”. Diagnostic
4 1. Check for aftermarket electronics, such as
transceiver, stereos, and anti theft devices. They
may radiate EMI into the control system if they are
improperly installed. (This may cause a false sensor
reading and turn on the MIL.)
Diagnostic Trouble Code (DTC) P1635 Reference Voltage # 1 Circuit Fault
D06RY00077
The TP sensor # 1 shares a 5 Volt reference with the Records data.
PCM.
If the PCM detects the 5 Volt reference for the TP sensor # Conditions for Clearing the MIL/DTC
1 is failure, DTCP1635 will be set.
Conditions for setting the DTC consecutive trip cycle during which the diagnostic has
been run and the fault condtion is no longer present.
D The ignition is “ON”. D A history DTC P1635will clear after 40 cosecutive trip
D The 5 Volt reference voltage for the TP sensor # 1 is cycle during which the warm up cycles have occurred
less than 4 volts. without a fault.
D The 5 Volt reference voltage for the TP sensor # 1 is D DTC P1635 can be cleared using the Tech 2 “Clear
more than 5 volts. Info” function or by disconnecting the PCM battery
feed. Tech2 “ Clear Info” function or by disconnecting
Action Taken When the DTC Sets the PCM battery feed.
lamp (MIL) .

1 Was the “On-Board(OBD)System Check” performed? Go to OBD
System
2. Using a DVM at the PCM side of the connector, Go to ETC
check the votage at terminal S38 (RED/BLU) pin. System
Is the voltage in specified range? 4.95 – 5.0V Check Go to Step 3
check the votage at terminal F20 (WHT) pin.
Is the voltage in specified range? 11.6 – 12.7V Go to Step 4 Go to Step 5
5 Observe the battery voltage and circuit. If the probrem
found, repair it as necessary.
Was the probrem found? — Verify repair Go to Step 6
6 Replace the PCM.
IMPORTANT:
D06RY00075

The AP sensor # 1shares a 5Volt reference with the PCM. D The PCM will turn the MIL “OFF” on the third
If the PCM detects the 5 Volt reference for the AP sensor consecutive trip cycle during which the diagnostic has
# 1 is failure, DTC P1635 will be set. been run and the fault condtion is no longer present.
Conditions for setting the DTC cycle during which the warm up cycles have occurred
without a fault.
D The ignition is “ON”.
D The 5 Volt reference voltage for the AP sensor # 1 is Info” function or by disconnecting the PCM battery
less than 4 volts. feed. Tech 2 “Clear Info” function or by disconnecting
D The 5 Volt reference voltage for the AP sensor # 1 is the PCM battery feed.
more than 5 volts.

lamp (MIL).
Records data.

System
2. Using a DVM at the PCM side of the connector, Go to ETC
check the votage at terminal S36 (BLK) pin. System
Is the voltage in specified range? 4.95 – 5.0V Check Go to Step 3
check the votage at terminal F20(WHT) pin.
5 Observe the battery voltage and circuit.
If the probrem found, repair it as necessary.
Was the probrem found? — Verify repair Go to Step 6
6 Replace the PCM.
IMPORTANT:
Diagnostic Trouble Code (DTC) P1640 Driver-1-Output Circuit Fault (ODM)

Output driver modules (ODMs) are used by the Check for the following conditions:
powertrain control module (PCM) to turn “ON” many of D Poor connection at PCM – Inspect harness connectors
the current-driven devices that are needed to control for backed-out terminals, improper mating, broken
various engine and transmission functions. Each ODM is locks, improperly formed or damaged terminals, and
capable of controlling up to 7 separate outputs by poor terminal-to-wire connection.
applying ground to the device which the PCM is D Damaged harness – Inspect the wiring harness for
commanding “ON.” damage, If the harness appears to be OK, disconnect
Unlike the Quad Driver Modules (QDMs) used in prior the PCM, turn the ignition “ON” and observe a
voltmeter connected to the suspect driver circuit at the
model years, ODMs have the capability of diagnosing PCM harness connector while moving connectors and
each output circuit individually. DTC P1640 set indicates wiring harnesses relates to the MIL. A change in
an improper voltage level has been detected on an ODM voltage will indicate the location of the fault.
output. D Poor connection at component – Examine for
Since A/C is an option, No A/C will cause the air damaged connectors, unplugged connector, or
conditioning clutch relay output to always fail. If a fault is damaged terminals at the following locations:
seen on the air conditioning clutch relay output, it will not Instrument cluster harness, canister purge solenoid,
be logged as a fault until the A/C request input interrupts a A/C clutch relay. An open ignition feed circuit at any of
these components will cause DTC P1640 to be set.
high voltage, indicating that A/C has been installed.
Conditions for Setting the DTC diagnostic test last failed may help determine how often
D Ignition “ON.” may assist in diagnosing the condition.
D Engine running.
D No DTC 1618. Test Description
D Ignition voltage is above 13.2 volts for 4 seconds. Number(s) below refer to the step number(s) on the
D Output voltage does not equal ignition voltage when Diagnostic Chart.
output is “OFF” or output voltage is not less than 1 volt 4. The Tech 2 Driver Module Status indicates the PCM
when output is “ON.” pin that is affected.
D Above conditions occur for at least 1 second.
9. The Tech 2 may indicate “short circuit” even when
Action Taken When the DTC Sets the problem is an open circuit. The cause of an
open circuit may be in the component itself-lamp,
D The PCM will not illuminate the malfunction indicator purge, solenoid, or A/C compressor relay.
lamp (MIL).
11.A short to ground on the ignition side of the
D The PCM will store conditions which were present component will blow the fuse. Since the fuse was
when the DTC was set as Failure Records only. This
information will not be stored as Freeze Frame data. checked in Step 2, a short to ground would be
between the affected component and the PCM.
warm-up cycles occur without a fault.
feed.
DTC P1640 – Driver-1-Output Circuit Fault (ODM)

performed? System
2 Check the fuse for the driver circuit that was shown as
faulty.
Was the fuse blown? — Go to Step 3 Go to Step 4
3 1. Check for a short to ground between the fuse and
the affected component.
2. Replace the fuse after making any necessary
repairs.
4 Disconnect the PCM connector for the affected driver
circuit.
Is there any damage to the PCM pin or connector? — Go to Step 5 Go to Step 6
6 Were either of the lamp circuits for “Check Engine” or
“Check Trans.” indicated as faulty by the Tech 2? — Go to Step 7 Go to Step 13
7 1. Leave the PCM connector for the lamp driver circuit
disconnected.
3. Using a DVM, check the voltage at the PCM
connector for the affected lamp driver circuit.
Was the voltage equal to the specified value? B+ Go to Step 15 Go to Step 8
2. Check for battery voltage at the fuse for the affected
lamp circuit.
Was battery voltage available at the fuse? — Go to Step 10 Go to Step 9
9 Repair the open circuit between the ignition switch and
the fuse.
2. Disconnect the PCM connector for the affected
driver terminal.
3. Connect an ohmmeter between a good ground and
the PCM connector for the affected driver.
Did the ohmmeter indicate continuity? — Go to Step 11 Go to Step 12
11 Repair the short to ground between the affected
component and its PCM driver terminal.
12 Repair the open circuit between the fuse and the PCM
driver terminal for the affected circuit.
DTC P1640 – Driver-1-Output Circuit Fault (ODM) (Cont'd)

13 1. Connect the PCM.
2. Start the engine and let it idle.
3. Backprobe the affected terminal at the PCM with a
DVM.
Was the voltage equal to the specified value? +B Go to Step 15 Go to Step 14
14 1. Run the engine at idle.
circuit.
15 Replace the PCM.
procedures.
Diagnostic Trouble Code (DTC) P1650 Quad Driver Module “A” Fault
The Quad Driver Module (QDMs) are used by the Check for the following conditions:
powertrain control module (PCM) to turn “ON” D Poor connection at PCM – Inspect harness connectors
current–driven devices that are needed to control two for backed-out terminals, improper mating, broken
engine functions. The PCM monitors open or short circuit locks, improperly formed or damaged terminals, and
of either of Canister Control Purge (CCP) Vent solenoid or poor terminal-to-wire connection.
Variable Intake Manifold (VIM). D Damaged harness – Inspect the wiring harness for
damage, If the harness appears to be OK, disconnect
Conditions for Setting the DTC the PCM, turn the ignition “ON” and observe a
voltmeter connected to the suspect driver circuit at the
D Ignition “ON”. PCM harness connector while moving connectors and
D Engine running. wiring harnesses relates to the MIL. A change in
D Ignition voltage. voltage will indicate the location of the fault.
D Output voltage does not equal voltage is not less than D Poor connection at component – Examine for
1 volt when out put is “ON”. damaged connectors, unplugged connector, or
damaged terminals at the following locations: canister
D Above conditions occur for at least 0.5 second. purge solenoid, fuel level sensor. An open ignition feed
circuit at any of these components will cause DTC
Action Taken When the DTC Sets P1650 to be set.
D The PCM will not illuminate the malfunction indicator Reviewing the Failure Records vehicle mileage since the
lamp (MIL). diagnostic test last failed may help determine how often
D The PCM will store conditions which were present the condition that caused the DTC to be set occurs. This
when the DTC was set as Failure Records only. This may assist in diagnosing the condition.
The following PCM pins are controlled by
Conditions for Clearing the MIL/DTC Quad driver modules (QDMs):
D The PCM will turn the MIL “OFF” on the third D S74 – VIM
consecutive trip cycle during which the diagnostic has D S7 – Canister control purge
D A history DTC P1650 will clear after 40 consecutive Test Description
Info” function or by disconnecting the PCM battery Diagnostic Chart.
feed. 4. The Tech 2 Driver Module Status indicates the PCM
pin that is affected.
9.The Tech 2 may indicate “short circuit” even when the
problem is an open circuit. The cause of an open
circuit may be in the component itself.
11.A short to ground on the ignition side of the
component will blow the fuse. Since the fuse was
checked in Step 2, a short to ground would be
between the affected component and the PCM.
DTC P1650 – Quad Driver Module (QDM) Fault

performed? System
2 Check the fuse for the driver circuit that was shown as
faulty.
Was the fuse blown? — Go to Step 5 Go to Step 6
3 1. Check for a short to ground between the fuse and
the affected component.
2. Replace the fuse after making any necessary
repairs.
4 Disconnect the PCM connector for the affected driver
circuit.
Is there any damage to the PCM pin or connector? — Go to Step 5 Go to Step 6
6 Were either of the lamp circuits for “Check Engine” or
“Check Trans.” indicated as faulty by the Tech 2? — Go to Step 7 Go to Step 13
7 1. Leave the PCM connector for the lamp driver circuit
disconnected.
3. Using a DVM, check the voltage at the PCM
connector for the affected lamp driver circuit.
Was the voltage equal to the specified value? B+ Go to Step 15 Go to Step 8
lamp circuit.
9 Repair the open circuit between the ignition switch and
the fuse.
2. Disconnect the PCM connector for the affected
driver terminal.
3. Connect an ohmmeter between a good ground and
the PCM connector for the affected driver.
Did the ohmmeter indicate continuity? — Go to Step 11 Go to Step 12
11 Repair the short to ground between the affected
component and its PCM driver terminal.
12 Repair the open circuit between the fuse and the PCM
driver terminal for the affected circuit.
DTC P1650 – Quad Driver Module (QDM) Fault (Cont'd)

13 1. Connect the PCM.
2. Start the engine and let it idle.
3. Backprobe the affected terminal at the PCM with a
DVM.
Was the voltage equal to the specified value? +B Go to Step 15 Go to Step 14
14 1. Run the engine at idle.
circuit.
15 Replace the PCM.
procedures.
Symptom Diagnosis an intermittent condition. Use the following feature to find

intermittent faults:
Preliminary Checks D Using a Tech 2’s “Freeze Frame” buffer or “Failure
Records” buffer can aid in locating an intermittent
Before using this section, perform the “On-Board
condition. Review and record the information in the
Diagnostic (OBD) System Check” and verify all of the
freeze frame or failure record associated with the
following items: intermittent DTC being diagnosed. The vehicle can
D The powertrain control module (PCM), and be driven within the conditions that were present
malfunction indicator lamp (MIL) (Check Engine when the DTC originally set.
lamp) and Reduced Power Lamp (RPL) are operating To check for loss of diagnostic code memory, disconnect
correctly. the MAP sensor and idle the engine until the MIL (Check
D There are no DTC(s) stored. Engine lamp) comes on. DTC P0107 should be stored
D Tech 2 data is within normal operating range. Refer to and kept in memory when the ignition is turned “OFF.” If
Typical Scan Data Values. not, the PCM is faulty. When this test is completed, make
D Verify the customer complaint and locate the correct sure that you clear the DTC P0107 from memory.
symptom in the table of contents. Perform the An intermittent MIL (Check Engine lamp) with no stored
procedure included in the symptom chart. DTC may be caused by the following:
D Ignition coil shorted to ground and arcing.
Visual/Physical Check D MIL (Check Engine lamp) wire to PCM shorted to
Several of the symptom procedures call for a careful ground.
visual/physical check. This can lead to correcting a D Poor PCM grounds. Refer to the PCM wiring
problem without further checks and can save valuable diagrams.
time. Check for improper installation of electrical options such
This check should include the following items: as lights, cellular phones, etc. Check all wires from the
D PCM grounds for cleanliness, tightness and proper PCM to the ignition coils for poor connections.
location. Check for an open diode across the A/C compressor
D Vacuum hoses for splits, kinks, and proper clutch and check for other open diodes (refer to wiring
connections, as shown on the “Vehicle Emission diagrams in Electrical Diagnosis).
Control Information” label. Check thoroughly for any If problem has not been found, refer to PCM Connector
type of leak or restriction. Symptom tables.
D Air intake ducts for collapsed or damaged areas. D Check the “Calibration ID” of the PCM, and compare it
D Air leaks at throttle body mounting area, mass air flow with the latest Isuzu service bulletins and/or Isuzu
(MAF) sensor and intake manifold sealing surfaces. EEPROM reprogramming equipment to determine if
D Ignition components for cracking, hardness, and an update to the PCM’s reprogrammable memory
carbon tracking. has been released. To check the “Calibration ID”,
connect the Tech 2, then look for “Powertrain”, then
D Wiring for proper connections, pinches and cuts. select “Calibration ID”. This identifies the contents of
the reprogrammable software and calibration
Intermittents contained in the PCM. If the “Calibration ID” is not the
IMPORTANT: An intermittent problem may or may not most current available, it is advisable to reprogram
turn on the malfunction indicator lamp (MIL) or store a the PCM’s EEPROM memory, which may either help
DTC. DO NOT use the Diagnostic Trouble Code (DTC) identify a hard-to-find problem or may fix the problem.
charts for intermittent problems. The fault must be D Calibration ID (example)
present to locate the problem.
Most intermittent problems are caused by faulty electrical Part number 9377709
connections or wiring. Perform a careful visual/physical Broadcast Code CYYD
check for the following conditions:
Identifier 801
D Poor mating of the connector halves or a terminal not
fully seated in the connector (backed out).
D Improperly formed or damaged terminal.
D All connector terminals in the problem circuit should
be carefully checked for proper contact tension.
D Poor terminal-to-wire connection. This requires
removing the terminal from the connector body to
check.
Road test the vehicle with a J 39200 Digital Multimeter
connected to a suspected circuit. An abnormal voltage
when the malfunction occurs is a good indication that
there is a fault in the circuit being monitored.
Use a Tech 2 to help detect intermittent conditions. The
scan tool has several features that can be used to locate
Hard Start Symptom

1 DEFINITION:
Engine cranks, but does not start for a long time. Does
eventually run, or may start but immediately stalls. Go to OBD
Was the “On-Board Diagnostic (OBD) System Check” System
performed? — Go to Step 2 Check
3 1. Perform a bulletin search.
2. If a bulletin that addresses the symptom is found,
correct the condition as instructed in the bulletin.
Was a bulletin found that addresses the symptom? — Verify repair Go to Step 4
4 Was a visual/physical check performed? Go to
Visual/Physic
— Go to Step 5 al Check
5 Check engine coolant temperature (ECT) sensor for
shift in value. After 8 hours with the hood up and the
engine not running, connect the Tech 2. With the
ignition “ON” and the engine not running, compare
engine coolant temperature to intake air temperature.
Are ECT and IAT within the specified value of each
other? ± 5°C (± 9°F) Go to Step 10 Go to Step 6
6 1. Using a Tech 2, display the engine coolant
temperature and note the value.
2. Check the resistance of the engine coolant
temperature sensor.
3. Refer to Engine Coolant Temperature Sensor
Temperature vs. Resistance chart on DTC P0118
Diagnostic Support for resistance specifications.
Is the resistance value near the resistance for the
temperature noted? — Go to Step 8 Go to Step 7
8 Locate and repair high resistance or poor connection in
the ECT signal circuit or the ECT sensor ground.
9 1. Check for a faulty, plugged, or incorrectly installed
PCV valve.
10 1. Check for water- or alcohol-contaminated fuel.
11 1. Perform the procedure in Fuel System Pressure
Test.
Hard Start Symptom (Cont'd)

12 1. Check for proper ignition voltage output with spark
tester J 26792 (ST-125). Refer to Electric Ignition
System for procedure.
13 1. Remove spark plugs. Check for wet plugs, cracks,
wear, improper gap, burned electrodes, or heavy
deposits. Refer to Electronic Ignition System.
NOTE: If spark plugs are gas or oil fouled, the cause of
the fouling must be determined before replacing the
spark plugs.
14 1. Check for a loose ignition coil ground and ION
Sensing module circuit.
15 1. Remove the ignition coils and check the ignition
coils for cracks or carbon tracking.
2. If a problem is found, replace affected coil(s) as
necessary.
16 1. Check for the following engine mechanical
problems (refer to Engine Mechanical):
D Low compression
D Leaking cylinder head gaskets
D Worn or incorrect camshaft
D Camshaft drive belt slipped or stripped
17 1. Review all diagnostic procedures within this table.
2. If all procedures have been completed and no
malfunctions have been found, review/inspect the
following:
D Visual/physical inspection
D Tech 2 data
D Freeze Frame data/Failure Records buffer
D All electrical connections within a suspected
circuit and/or system.
Contact
3. If a problem is found, repair as necessary. Technical
Was a problem found? — Verify repair Assistance
Surges and/or Chuggles Symptom

1 DEFINITION:
Engine power variation under steady throttle or cruise.
Feels like the vehicle speeds up and slows down with
no change in the accelerator pedal.
Go to OBD
Visual/Physic
5 Be sure that the driver understands transmission
torque converter clutch and A/C compressor operation
as explained in the owner’s manual.
Inform the customer how the TCC and the A/C clutch
operate.
Is the customer experiencing a normal condition? — System OK Go to Step 6
6 1. Check the the fuel control heated oxygen sensors
(HO2S, B1S1 and B2S1). The fuel control heated
oxygen sensors (HO2S) should respond quickly to
different throttle positions. If they don’t, check them
for silicone or other contaminants from fuel or use of
improper RTV sealant. The sensors may have a
white powdery coating.
Silicon contamination causes a high but false
HO2S signal voltage (rich exhaust indication).
The PCM will then reduce the amount of fuel
delivered to the engine, causing a severe
driveability problem. For more information, refer
to Powertrain Control Module (PCM) and Sensors.
7 1. Check the fuel pressure. Refer to Fuel System
Pressure Test.
8 Monitor the long term fuel trim on the Tech 2.
Is the long term fuel trim significantly in the negative
range (rich condition)? — Go to Step 9 Go to Step 10
9 1. Check items that can cause the engine to run rich.
Refer to Diagnostic Aids in DTC P0172 Diagnostic
Support.
Was a problem found? — Go to Step 11 Verify repair
Surges and/or Chuggles Symptom (Cont'd)

10 1. Check items that can cause the engine to run lean.
Refer to Diagnostic Aids in DTC P0171.
Was a problem found? — Go to Step 11 Verify repair
tester J 26792 (ST-125). Refer to Electric Ignition
13 1. Check the ignition coils for cracks or carbon
tracking.
14 1. Remove the spark plugs and check for wet plugs,
cracks, wear, improper gap, burned electrodes, or
heavy deposits. Refer to Electronic Ignition
System.
spark plugs.
15 1. Check the injector connections.
2. If any of the injector connectors are connected to an
incorrect cylinder, correct as necessary.
16 1. Check PCM grounds for the cleanliness, tightness
and proper locations. Refer to the PCM wiring
diagrams in Electrical Diagnosis.
17 1. Check MAF sensor connections.
2. If a problem is found, replace the faulty terminals as
necessary. Refer to Electrical Diagnosis for wiring
repair procedures.
18 1. Visually/physically check vacuum hoses for splits,
kinks, and proper connections and routing as
shown on the “Vehicle Emission Control
Information” label.
Surges and/or Chuggles Symptom (Cont'd)

19 1. Check the exhaust system for possible restriction:
D Inspect the exhaust system for damaged or
collapsed pipes.
D Inspect the muffler for heat distress or possible
internal failure.
D Check for a possible plugged three-way
catalytic converter by checking the exhaust
system back pressure. Refer to Restricted
Exhaust System Check.
following:
D Tech 2 data
Contact
Lack of Power, Sluggish or Spongy Symptom

1 DEFINITION:
Engine delivers less than expected power. Little or no
increase in speed when accelerator pedal is pushed
down part-way.
Go to OBD
Visual/Physic
5 1. Remove and check the air filter element for dirt or
restrictions. Refer to Air Intake System in
ON-Vehicle Service.
Was a repair required? — Verify repair Go to Step 6
6 1. Check for low fuel pressure. Refer to Fuel System
Pressure Test.
7 1. Check for water- or alcohol-contaminated fuel.
3. On the Tech 2, select F3: Miscellaneous Test, F6:
Variable Intake Manifold.
4. Repeat Switch ON or OFF of VIM solenoid valve by
using the Tech 2.
5. Check to see if the actuator works normally.
tester J 26792 (ST-125). Refer to Electronic Ignition
Lack of Power, Sluggish or Spongy Symptom (Cont'd)

10 1. Remove the spark plugs and check for wet plugs,
System.
spark plugs.
tracking.
12 1. Check the PCM grounds for the cleanliness,
tightness and proper locations. Refer to the PCM
wiring diagrams in Electrical Diagnosis.
collapsed pipes.
internal failure.
14 1. Check the torque converter clutch (TCC) for proper
operation. Refer to 4L30-E Transmission
Diagnosis.
15 1. Check for an engine mechanical problem. Check
for low compression, incorrect or worn camshaft,
loose timing belt, etc. Refer to Engine Mechanical.
following:
D Tech 2 data
Contact
Detonation/Spark Knock Symptom

1 DEFINITION:
A mild to severe ping, usually worse under acceleration.
The engine makes sharp metallic knocks that change
with throttle opening.
Go to OBD
Visual/Physic
4 If Tech 2 readings are normal (refer to Typical Scan
Values) and there are no engine mechanical faults, fill
the fuel tank with a known quality gasoline that has a
minimum octane rating of 87 and re-evaluate the
vehicle performance.
Is detonation present? — Go to Step 5 Verify repair
5 1. Check the transmission range switch circuit. Use a
Tech 2 and be sure the Tech 2 indicates that the
vehicle is in drive with the gear selector in drive or
overdrive.
2. If a problem is found, diagnose and repair the
transmission range switch as necessary (refer to
4L30-E Automatic Transmission Diagnosis).
6 1. Check TCC operation. Refer to 4L30-E
Transmission Diagnosis.
7 1. Check for obvious overheating problems:
D Low engine coolant.
D Restricted air flow to radiator, or restricted
water flow through radiator.
D Correct coolant solution should be a 50/50 mix
of approved antifreeze/coolant and water.
Refer to Engine Cooling.
D EGR operation. Refer to DTC P0401.
D ION sensing module fault.
2. Disconnect the ION sensing module.
9 Check the ION sensing harness between the PCM
(F68) and ION sensing module circuit (RED Wire) at
the Kl line harness connector.
Detonation/Spark Knock Symptom (Cont'd)

11 Check the ION sensing harness between the ignition
coil and ION sensing module circuit at the DC motor
harness connector.
necessary.
1. ION sensing module ground circuit for a poor
connection.
necessary.
15 Replace the ION sensing module.
16 1. Check fuel pressure. Refer to Chart Fuel System
Pressure Test.
17 1. Check items that can cause an engine to run lean
(long term fuel trim significantly in the positive
range). For a lean condition, refer to Diagnostic
Aids in DTC P0171 Diagnostic Support.
18 1. Spark plugs for proper heat range. Refer to General
Information.
2. If incorrect spark plugs are installed, replace spark
plugs as necessary.
Did any spark plugs require replacement? — Verify repair Go to Step 19
19 1. Remove excessive carbon buildup with a top engine
cleaner. Refer to instructions on the top engine
cleaner can.
2. Re-evaluate vehicle performance.
Is detonation still present? — Go to Step 20 Verify repair
Detonation/Spark Knock Symptom (Cont'd)

20 1. Check for an engine mechanical problem. Perform
a cylinder compression check. Refer to Engine
Mechanical.
following:
D Tech 2 data
Contact
Rough, Unstable, or Incorrect Idle, Stalling Symptom

1 DEFINITION:
Engine runs unevenly at idle. If severe, the engine or
vehicle may shake. Engine idle speed may vary in
RPM. Either condition may be severe enough to stall
the engine.
Go to OBD
Was a bulletin found that addresses the symptom? — Go to Step 14 Go to Step 4
Visual/Physic
5 1. Check the PCM grounds for cleanliness, tightness
and proper routing. Refer to the PCM wiring
6 Observe the long term fuel trim on the Tech 2.
Support.
8 Is the long term fuel trim significantly in the positive
range (lean condition)? — Go to Step 9 Go to Step 10
Support.
10 1. Check for incorrect idle speed. Ensure that the
following conditions are present:
D The engine is fully warm.
D The accessories are “OFF.”
2. Using a Tech 2, monitor the Engine Speed. Desired Idle
Is the Engine Speed within the specified values? Speed Go to Step 12 Go to Step 11
Rough, Unstable, or Incorrect Idle, Stalling Symptom (Cont'd)

11 1. Visually/physically inspect for the following
conditions:
D Restricted air intake system. Check for a
possible collapsed air intake duct, restricted
air filter element, or foreign objects blocking
the air intake system.
D Large vacuum leak. Check for a condition that
causes a large vacuum leak, such as an
incorrectly installed or faulty crankcase
ventilation valve or a disconnected brake
booster hose.
12 Check the injector connections. If any of the injectors
are connected to an incorrect cylinder, correct as
necessary.
13 1. Perform the “Injector Coil/Balance Test” in Fuel
Metering System.
14 1. Check for fuel in the pressure regulator vacuum
hose.
2. If fuel is present, replace the fuel pressure regulator
assembly. Refer to Fuel Metering System.
System for the procedure.
spark plugs.
Sensing Module circuit.
18 1. Check ignition coils for cracks or carbon tracking.
Rough, Unstable, or Incorrect Idle, Stalling Symptom (Cont'd)

19 Using a Tech 2, monitor the throttle position 1 and 2
Refer to DTC
angle with the engine idling.
for further
Is the TP angle at the specified value and steady? 8 ∼ 10% Go to Step 20 diagnosis
20 1. Check the positive crankcase ventilation (PCV)
valve for proper operation. Refer to Crankcase
Ventilation System.
overdrive.
22 1. Check for the following engine mechanical items.
Refer to Engine Mechanical for diagnosis
procedures:
D Low compression
D Sticking or leaking valves
D Worn camshaft lobe(s)
D Worn rocker arms
D Broken valve springs
23 1. Check for faulty motor mounts. Refer to Engine
Mechanical for inspection of mounts.
following:
D Tech 2 data
Contact
Poor Fuel Economy Symptom

1 DEFINITION:
Fuel economy, as measured by an actual road test, is
noticeably lower than expected. Also, economy is
noticeably lower than it was on this vehicle at one time,
as previously shown by an actual road test.
(Non-standard tires will cause odometer readings to be
incorrect, and that may cause fuel economy to appear
poor when it is actually normal.)
Go to OBD
Visual/Physic
4 Check owner’s driving habits.
D Is the A/C “ON” full time (defroster mode “ON”)?
D Are tires at the correct pressure?
D Are excessively heavy loads being carried?
D Is acceleration too much, too often?
5 Review the items in Step 4 with the customer and
advise as necessary.
Is the action complete? — System OK —
6 1. Visually/physically check: Vacuum hoses for splits,
kinks, and improper connections and routing as
7 1. Remove and check the air filter element for dirt or for
restrictions. Refer to Air Intake System.
Was a repair required? — Verify repair Go to Step 8
8 1. Remove spark plugs and check for wet plugs,
heavy deposits. Refer to Spark Plug Replacement.
spark plugs.
9 1. Check for low engine coolant level. Refer to Engine
Cooling.
Poor Fuel Economy Symptom (Cont'd)

10 1. Check for an incorrect or faulty engine thermostat.
Refer to Engine Cooling.
11 1. Check for low engine compression. Refer to Engine
Mechanical.
12 1. Check the TCC operation. Refer to 4L30-E
Transmission Diagnosis.
collapsed pipes.
internal failure.
14 Check for proper calibration of the speedometer.
Does the speed indicated on the speedometer closely
match the vehicle speed displayed on the Tech 2? — Go to Step 16 Go to Step 15
15 Diagnose and repair an inaccurate speedometer
condition as necessary. Refer to Vehicle Speed
Sensor in Electrical Diagnosis.
16 1. Check the air intake system and the crankcase for
air leaks. Refer to Air Intake System and
Crankcase Ventilation System.
2. When all procedures have been completed and no
following:
D Tech 2 data
D All connections within a suspected circuit
and/or system.
18 Perform the procedure in Fuel System Pressure Test. Contact
Technical
Was the fuel pressure normal?
— Assistance Verify repair
Excessive Exhaust Emissions or Odors Symptom

1 DEFINITION:
Vehicle fails an emission test. Vehicle has excessive
“rotten egg” smell. (Excessive odors do not necessarily
indicate excessive emissions.)
Go to OBD
3 Was a thorough visual/physical check performed? Go to
Visual/Physic
4 1. Check for vacuum leaks. Check vacuum lines,
intake manifold, throttle body, etc.
Were any vacuum leaks located? — Go to Step 13 Go to Step 5
5 1. Check the fuel cap for proper installation.
2. Secure the fuel cap if necessary.
Was the fuel cap installed properly? — Go to Step 6 Go to Step 13
6 1. Check the fuel pressure. Perform the procedure in
Fuel System Pressure Test.
7 1. Check for a faulty, plugged, or incorrectly installed
crankcase ventilation valve; also check the
crankcase ventilation system for plugging.
8 1. Check the injector connections.
2. If any of the injectors are connected to an incorrect
cylinder, correct as necessary.
Metering System.
10 1. Refer to Engine Cooling for cooling system
diagnosis.
11 1. Check EVAP canister for fuel loading. Refer to
Evaporative Emission Control System.
Excessive Exhaust Emissions or Odors Symptom (Cont'd)

12 1. Remove excessive carbon buildup with a top engine
cleaner. Refer to the instructions on the top engine
cleaner can.
2. Perform the exhaust emission test.
Does the vehicle pass the test? — System OK Go to Step 14
13 Perform the exhaust emission test.
14 Does the exhaust emission test indicate excessive CO
and HC levels or is long term fuel trim significantly in the
negative range (rich condition)? — Go to Step 15 Go to Step 16
Support. Make any necessary repairs.
Support. Make any necessary repairs.
17 1. Check the EGR system (refer to DTC P0401).
18 1. Check for an engine mechanical problem.
Perform a cylinder compression check (refer to
Engine Mechanical).
following:
D Tech 2 data
D Freeze Frame data/Failure Records butter
Contact
Dieseling, Run-On Symptom

1 DEFINITION:
Engine continues to run after key is turned “OFF,” but
runs very rough. If engine runs smooth, check ignition
switch and adjustment.
Go to OBD
Visual/Physic
4 1. Check for a short between B+ and any of the ignition
feed circuits.
following:
D Tech 2 data
circuit and/or system
Contact
Backfire Symptom
1 DEFINITION:
Fuel ignites in the intake manifold, or in the exhaust
system, making a loud popping noise. Go to OBD
Visual/Physic
4 1. Check for proper ignition voltage coil output with
spark tester J 26792 (ST-125). Refer to Electric
Ignition System for procedure.
System.
spark plugs. Refer to DTC P0172 to determine the
cause of a rich condition or Engine Mechanical for an oil
fouling condition.
6 1. Visually/physically inspect the ignition coils for
cracks.
7 1. Check for an intermittent ignition system
malfunction:
D Intermittent CKP 58X signal.
D Intermittent ignition feed circuit or sensor
ground circuit to the crankshaft position
sensor.
Pressure Test.
Backfire Symptom (Cont'd)

9 1. Check for the following engine mechanical
conditions.
procedures:
D Low compression
10 1. Check the intake and exhaust manifold(s) for
casting flash. Refer to Engine Mechanical.
following:
D Tech 2 data
Contact
Cuts Out, Misses Symptom

1 DEFINITION:
Steady pulsation or jerking that follows engine speed;
usually more pronounced as engine load increases. Go to OBD
Visual/Physic
5 1. Check the PCM grounds for clearness, tightness
6 Observe the long term fuel trim on the Tech 2.
Support.
8 Is the long term fuel trim significantly in the positive
range (lean condition)? — Go to Step 9 Go to Step 10
Support.
10 1. Check for incorrect idle speed. Ensure that the
following conditions are present:
D The engine is fully warm.
D The accessories are “off.”
2. Using a Tech 2, monitor the Engine Speed. Desired Idle
Is the Engine Speed within the specified values? Speed Go to Step 12 Go to Step 11
Cuts Out, Misses Symptom (Cont'd)

11 1. Visually/physically inspect for the following
conditions:
D Restricted air intake system. Check for a
possible collapsed air intake duct, restricted
air filter element, or foreign objects blocking
the air intake system.
D Large vacuum leak. Check for a condition that
causes a large vacuum leak, such as an
incorrectly installed or faulty PCV valve or
brake booster hose disconnected .
12 Check the injector connections. If any of the injectors
are connected to an incorrect cylinder, correct as
necessary.
Metering System.
14 1. Check for fuel in the pressure regulator vacuum
hose.
2. If fuel is present, replace the fuel pressure regulator
assembly. Refer to Fuel Metering System.
spark plugs.
18 1. Check ignition coils for cracks or carbon tracking.
19 Using a Tech 2, monitor the TP 1, 2 angle with the Refer to DTC
engine idling. P0123 for
further
Is the TP angle at the specified value and steady?
8 ∼ 10% Go to Step 20 diagnosis
Cuts Out, Misses Symptom (Cont'd)

20 1. Check the PCV valve for proper operation. Refer to
Crankcase Ventilation System.
overdrive.
22 1. Check the following engine mechanical items.
procedures:
D Low compression
D Worn rocker arms
D Broken valve springs
23 1. Check for faulty motor mounts. Refer to Engine
Mechanical for inspection of mounts.
following:
D Tech 2 data
Contact
Hesitation, Sag, Stumble Symptom

1 DEFINITION:
Momentary lack of response as the accelerator is
pushed down. Can occur at any vehicle speed. Usually
most pronounced when first trying to make the vehicle
move, as from a stop sign. May cause the engine to stall
if severe enough.
Go to OBD
Visual/Physic
5 1. Check the fuel control heated oxygen sensors
(HO2S, B1S1 and B2S1). The fuel control heated
oxygen sensors (HO2S) should respond quickly to
different throttle positions. If they don’t, check them
for silicon or other contaminants from fuel or use of
improper RTV sealant. The sensors may have a
white powdery coating.
Silicon contamination causes a high but false
HO2S signal voltage (rich exhaust indication).
The PCM will then reduce the amount of fuel
delivered to the engine, causing a severe
driveability problem. For more information, refer
to Powertrain Control Module (PCM) and Sensors.
Pressure Test.
7 Observe the TP 1, 2 angle display on the Tech 2 while
slowly increasing throttle pedal.
Does the TP angle display steadily increase from 8 ∼
10% at closed throttle to 90 ∼ 92% at WOT? — Go to Step 8 Go to Step 19
8 Monitor the long term fuel trim on the Tech 2.
Support.
Hesitation, Sag, Stumble Symptom (Cont'd)

Support.
tracking.
System.
spark plugs.
15 1. Check the PCM grounds for clearness, tightness
16 1. Check the MAF sensor connections.
2. If a problem is found, replace the faulty terminals as
necessary. Refer to Electrical Diagnosis for wiring
repair procedures.
Hesitation, Sag, Stumble Symptom (Cont'd)

17 1. Visually/physically check vacuum hoses for splits,
kinks, and proper connections and routing as
following:
D Tech 2 data
Contact
Bank 1 Restricted Exhaust System Check

performed? System
2 1. Remove the Bank 1 HO2S 2.
2. Install the Exhaust Backpressure Tester
(BT-8515-V or equivalent) in place of the Bank 1
HO2S 2.
3. Run the engine at normal operating temperature.
4. Increase the engine speed to 2000 RPM and allow
10 seconds for pressure to build.
5. Observe the exhaust system backpressure reading
on the gauge.
Does the reading exceed the amount in the value 8.62 kPa
column? (1.25 psi) Go to Step 3 Go to Step 4
3 Repair the restriction in the exhaust system after the
catalytic converter.
Possible faults include:
D Collapsed pipe
D Heat distress
D Internal muffler failure
4 1. Install the Bank 1 HO2S 2.
2. Install the Exhaust Backpressure Tester in place of
Bank 1 HO2S 1.
4. Increase the engine speed to 2000 RPM and allow No trouble
10 seconds for pressure to build. found. If a
driveability
5. Observe the exhaust system backpressure reading symptom
on the gauge. exists, refer
Does the reading exceed the amount in the value 8.62 kPa to symptom
column? (1.25 psi) Go to Step 5 charts
5 Repair the restriction in the catalytic converter.
NOTE: DTCs will be set by running the vehicle to normal
operating temperature after a cold start with the O2
sensor disconnected. After performing these tests, use
the Tech 2 to erase the DTCs that were set by the lack of
O2 sensor activity.
Bank 2 Restricted Exhaust System Check

performed? System
2 1. Remove the Bank 2 HO2S 2.
2. Install the Exhaust Backpressure Tester
(BT-8515-V or equivalent) in place of the Bank 2
HO2S 2.
4. Increase the engine speed to 2000 RPM and allow
10 seconds for pressure to build.
5. Observe the exhaust system backpressure reading
on the gauge.
Does the reading exceed the amount in the value 8.62 kPa
column? (1.25 psi) Go to Step 3 Go to Step 4
3 Repair the restriction in the exhaust system after the
catalytic converter.
Possible faults include:
D Collapsed pipe
D Heat distress
D Internal muffler failure
4 1. Install the Bank 2 HO2S 2.
2. Install the Exhaust Back pressure Tester in place of
Bank 1 HO2S 1.
4. Increase the engine speed to 2000 RPM and allow No trouble
10 seconds for pressure to build. found. If a
driveability
5. Observe the exhaust system backpressure reading symptom
on the gauge. exists, refer
Does the reading exceed the amount in the value 8.62 kPa to symptom
column? (1.25 psi) Go to Step 5 charts
5 Repair the restriction in the catalytic converter.
NOTE: DTCs will be set by running the vehicle to normal
operating temperature after a cold start with the O2
sensor disconnected. After performing these tests, use
the Tech 2 to erase the DTCs that were set by the lack of
O2 sensor activity.
Default Matrix Table

Service Procedure Default Strategy
A referral strategy has been established to assist the
technician with additional information when the cause of
the failure cannot be determined. If no problem is found
after performing diagnostics, then refer to the default
matrix table for further diagnostic information.
Default Matrix Table
Strategy Based Diagnostic Charts Initial Diagnosis Default Section(s)

On-Board Diagnostic (OBD) System Vehicle does not enter diagnostics. Chassis Electrical
Check
On-Board Diagnostic (OBD) System Vehicle enters diagnostics and Ignition System Check
Check communicates with the Tech 2. MIL is
“ON” in diagnostics. Engine does not
start and run.
On-Board Diagnostic (OBD) System Engine starts and runs, no PCM —
Check codes set. Customer complains of
vibration.
On-Board Diagnostic (OBD) System Engine starts and runs, no PCM Automatic Transmission
harsh or soft shift, poor performance,
delayed or no engagement into drive
or reverse, transmission fluid leak,
transmission noise or vibration, or
improper TCC operation.
PCM Power and Ground Check On-Board Diagnostic (OBD) System Chassis Electrical
Check.
PCM Power and Ground Check On-Board Diagnostic (OBD) System Chassis Electrical
Check. PCM power and ground
circuits OK. Data link voltage
incorrect.
On-Board Diagnostic (OBD) System Engine starts and runs, no PCM Automatic Transmission
harsh or soft shift, poor performance,
delayed or no engagement into drive
or reverse, transmission fluid leak,
transmission noise or vibration, or
improper TCC operation.
Symptoms Initial Diagnosis Default Section(s)

Intermittents 1. On-board Diagnostic (OBD) Chassis Electrical
system check.
2. Careful visual/physical
inspections.
Hard Starts 1. OBD system check. Engine Mechanical, Ignition
2. ETC system check. System Check, Exhaust System
Diagnosis
3. Sensors (ECT, MAP, MAF, TP) ;
MAP output chart.
4. Fuel system electrical test, fuel
system diagnosis.
5. Ignition system.

Surges and/or Chuggles 1. OBD system check. Calibration ID/Service Bulletins,
2. ETC system check. Ignition System Check,
Generator Output, Exhaust
3. Heated oxygen sensors.
System Diagnosis, 4L30-E
4. Fuel system diagnosis. System Test
5. Ignition system.
Lack of Power, Sluggish or Spongy 1. OBD system check. Refer to Exhaust System in
2. ETC system check. Engine Exhaust, TCC Operation,
Calibration ID/Service Bulletins
3. Fuel system diagnosis.
4. Ignition system.
5. EGR operation.
6. EGR system check.
Detonation/Spark Knock 1. OBD system check. TCC operation, Cooling System,
2. Transmission range switch. Ignition System Check,
Calibration ID/Service Bulletins
3. EGR operation.
4. EGR system check.
5. TCC operation.
7. Ignition system.
8. ION sensing module check.
Rough, Unstable, or Incorrect Idle, 1. OBD system check. MAP Output Check, Throttle
Stalling 2. ETC system check. Linkage, EGR System Check,
A/C Clutch Control Circuit
3. Fuel injector and fuel injector
Diagnosis, Crankcase Ventilation
balance test.
System, Calibration ID/Service
4. EVAP emission canister purge Bulletins, Generator Output
valve check. Voltage (refer to Chassis
5. Ignition system. Electrical), Exhaust Diagnosis
6. EGR operation.
Poor Fuel Economy 1. OBD system check. TCC Operation, Exhaust System
2. Careful visual/physical inspection. (refer to Engine Exhaust)
3. Ignition system.
4. Cooling system.
Hesitation, Sag, Stumble 1. OBD system check. EGR Operation, EGR System
2. ETC system check. Check, Generator Output
Voltage (refer to Chassis
3. TP.
Electrical), Calibration ID/Service
4. MAP output check. Bulletins, Ignition System Check
balance test.
7. EVAP emission canister purge
valve.
8. Ignition system.
Cuts Out, Misses 1. OBD system check. Ignition System Check
2. Cylinder balance test.
3. ETC system check.
Engine Cranks But Will Not Run 1. OBD system check. Fuel System Electrical
Diagnosis, Fuel System
Diagnosis, Fuel Injector and Fuel
Injector Balance Test.

Excessive Exhaust Emissions or 1. OBD system check. EGR System Check, Exhaust
Odors 2. Emission test. Diagnosis, Calibration ID/Service
Bulletins
3. Cooling system.
balance test.
6. EVAP emission canister purge
valve.
7. Crankcase ventilation system.
8. Ignition system.
9. MAP output check.
Dieseling, Run-On 1. OBD system check. —
2. Careful visual/physical inspection.
Backfire 1. OBD system check. Exhaust System Diagnosis,
2. Ignition system. Intake Casting Flash, Ignition
System Check
balance test.
5. EGR operation, EGR system
check.
Misfire 1. OBD system check. Vibrations, Transmission,
2. Ignition system. Driveshaft and Axle
balance test.
Catalyst Monitor 1. OBD system check. Exhaust System
3. Heated oxygen sensors.
Fuel Trim 1. OBD system check. Exhaust System Intake Air
2. Careful visual/physical inspection. System
4. Heated oxygen sensors, MAF
sensors.
Evaporative Emissions 1. OBD system check. —
Heated Oxygen Sensors 1. OBD system check. Exhaust System
On-Vehicle ServiceCamshaft 3. Lubricate the new O-ring with engine oil.

4. Install the lubricated O-ring.
Position (CMP) Sensor
Installation Procedure
Removal Procedure
1. Install the CMP sensor in the cylinder head.
1. Disconnect the negative battery cable.
2. Install the CMP sensor retaining bolt.
2. Remove the engine cover.
Tighten
3. Remove the common chamber assembly.
D Tighten the retaining screw to 9 N·m (78 lb in.).
Refer to Common Chamber in Engine Mechanical
section. 3. Connect the electrical connector to the CMP sensor.
014RV053
014RW120
4. Install the common chamber assembly.
4. Disconnect the electrical connector to the CMP
sensor. Refer to Common Chamber in Engine Mechanical
section.
014RV053
5. Remove the CMP retaining bolt from the side of left 014RW164
cylinder head. 5. Install the engine cover.

6. Remove the CMP sensor from the cylinder head. 6. Connect the negative battery cable.
Inspection Procedure
1. Inspect the sensor O-ring for cracks or leaks.
2. Replace the O-ring if it is worn or damaged.
Crankshaft Position (CKP)

Sensor
Removal Procedure
2. Disconnect the electrical connector to the CKP
sensor.
3. Remove one bolt and the CKP sensor from the right
side of the engine block, just behind the mount.
NOTE: Use caution to avoid any hot oil that might drip
out.
TS22909
3. Connect the electrical connector to the CKP sensor.

4. Connect the negative battery cable.
Engine Coolant Temperature

(ECT) Sensor
Removal Procedure
NOTE: Care must be taken when handling the engine
coolant temperature (ECT) sensor. Damage to the ECT
sensor will affect proper operation of the fuel injection
system.
TS22909

Inspection Procedure 2. Drain the radiator coolant. Refer to Draining and
Refilling Cooling System in Engine Cooling section.
1. Inspect the sensor O-ring for cracks or leaks. 3. Disconnect the electrical connector.
2. Replace the O-ring if it is worn or damaged.
3. Lubricate the new O-ring with engine oil.
4. Install the lubricated O-ring.
1. Install the CKP sensor in the engine block.
2. Install the CKP sensor mounting bolt.
Tighten
D Tighten the mounting bolt to 9 N·m (78 lb in.).
014RY00001
4. Remove the ECT sensor from the coolant crossover. 3. Connect the electrical connector.
014RY00002 014RY00003
4. Fill the radiator with coolant. Refer to Draining and

Installation Procedure Refilling Cooling System in Engine Cooling section.
1. Apply sealer or the equivalent to the threads of the
ECT sensor.
2. Install the ECT sensor in the coolant crossover. Heated Oxygen Sensor (HO2S)
Tighten
D Tighten the ECT sensor to 30 N·m (22 lb ft.). Removal Procedure
2. Locate the four oxygen sensors.
014RY00002
060RW008
D Bank 1 sensor 1 is mounted on the exhaust pipe D Bank 2 sensor 1 is mounted on the exhaust pipe
ahead of the right-hand catalytic converter. ahead of the left-hand catalytic converter.
TS22912 TS22914
D Bank 1 sensor 2 is mounted behind the right-hand D Bank 2 sensor 2 is mounted behind the left-hand
catalytic converter. catalytic converter.
TS22913 TS22915
3. Disconnect the pigtail from the wiring harness. 2. Inspect the louvered end of the sensor for grease,
dirt, or other contaminations.
060RY00017
IMPORTANT: The pigtail is permanently attached to 060RY00017
the sensor. Be careful not to pull the wires out.

NOTE: Do not use a torch to remove an HO2S unless the Installation Procedure
sensor is being replaced. Using a torch could damage the IMPORTANT:
sensor.
D A special anti-seize compound on the HO2S threads.
4. Remove the sensor from the exhaust pipe. This compound consists of glass beads suspended in
D Because of the expansion and contraction of the a liquid graphite solution. The graphite burns away
metal in the exhaust system over time, this may be with engine heat, but the glass beads will remain,
difficult if the engine temperature is below 48°C making the sensor easier to remove.
(120°F). D New or service sensors will already have the
compound applied to the threads. If a sensor is
removed and is to be reinstalled for any reason, the
threads must have anti-seize compound applied.
1. Apply anti-seize compound or the equivalent to the
threads of the oxygen sensor, if necessary.
2. Install the oxygen sensor on the exhaust pipe in its
original position.
Tighten
D Tighten the oxygen sensor to 55 N·m (40 lb ft.).
060RY00017
All four sensors are identical. Inspect each in the same
way.
1. Inspect the pigtail and the electrical connector for
grease, dirt, corrosion, and bare wires or worn
insulation.
060RY00017
3. Connect the pigtail to the wiring harness.
Intake Air Temperature (IAT)

Sensor
Removal Procedure
2. Remove the engine cover
3. The IAT sensor is located in the intake air duct, behind
the throttle body.
4. Disconnect the electrical connector from the IAT
sensor.
TS23741
3. Install the engine cover.

ION Sensing Module

Removal Procedure
2. Disconnect the ION sensing module connector.
3. Remove the bolts and the ION sensing module from
the common chamber.
TS23741
5. Remove the IAT sensor from the intake air duct by

using a rocking motion while pulling the sensor.
1. Install the IAT sensor into the grommet in the intake
air duct.
2. Correct the IAT electrical connector.
060RY00087
1. Install the ION sensing module on the common
chamber with the bolts.
Tighten
D Tighten the ION sensing module to 4 N·m (35 lb
in.).
2. Connect the ION sensing module connectors as 3. Loosen the clamps which secure the intake air duct
shown in the illustration. and the air cleaner to the MAF sensor.
4. Remove the intake air duct from the MAF sensor.
5. Remove the MAF sensor from the air cleaner.
060RY00111
Legend
(1) Green Color Connector TS23781
(2) Blue Color Connector

(3) Identification Mark (6VE1 Engine Only) Installation Procedure
3. Connect the negative battery cable. 1. Install the MAF sensor on the air cleaner with the
clamp.
2. Install the intake air duct and the clamp on the MAF
Mass Air Flow (MAF) Sensor sensor.
Removal Procedure
2. Disconnect the electrical connector from the MAF
sensor.
TS23781
3. Tighten the clamps to secure the MAF sensor to the

intake air duct and the air cleaner.
4. Connect the MAF electrical connector.
TS23740
Manifold Absolute Pressure Installation Procedure

(MAP) Sensor 1. Install the MAP sensor in the mounting bracket.
Removal Procedure
2. Disconnect the electrical connector from the MAP
sensor.
055RW002
2. Install the mounting bracket retaining bolt on the

common chamber.
Tighten
D Tighten the bolt to 20 N·m (12 lb ft.).
3. Connect the MAP electrical connector.
055RY00001
3. Remove the bolt securing the MAP sensor to the

mounting bracket on the common chamber.
4. Remove the MAP sensor from the mounting bracket.
055RY00001
055RW002
Malfunction Indicator Lamp D Do not touch the control module connector pins or
soldered components on the control module circuit
(MIL) board.
D Do not open the replacement part package until the
Removal and Installation Procedure part is ready to be installed.
D Before removing the part from the package, ground
Refer to Warning light bulb, indicator light valve,
the package to a known good ground on the vehicle.
illumination light bulb, A/T indicator light bulb in Meter and
Gauge. D If the part has been handled while sliding across the
seat, or while sitting down from a standing position, or
while walking a distance, touch a known good ground
Reduced Power Lamp before installing the part.
NOTE: To prevent internal PCM damage, the ignition
must be in the “OFF” position in order to disconnect or
reconnect power to the PCM (for example: battery cable,
The reduced power lamp (PPL) turns on when the ignition
PCM pigtail, PCM fuse, jumper cables, etc.).
key is moved to the ON position. It should turn off in
approximately 3 seconds or immediately after the engine IMPORTANT: When replacing the production PCM
starts. with a service PCM, it is important to transfer the
If the RPL turns on during vehicle operation, a vehicle broadcast code and production PCM number to the
system failure resulting in reduced engine output is service PCM label. This will allow positive identification of
indicated. PCM parts throughout the service life of the vehicle. Do
If both the reduced RPL and the check engine light turn not record this information on the metal PCM cover.
on, a serious problem affecting vehicle performance is
indicated. IMPORTANT: The ignition should always be in the
Refer to the OBD system check NO and RPL “ON” steady “OFF” position in order to install or remove the PCM
in this manual. connectors.
Service of the PCM should normally consist of either re-
placement of the PCM or EEPROM programming. If the
Powertrain Control Module diagnostic procedures call for the PCM to be replaced,
(PCM) the PCM should be checked first to ensure it is the correct
part. If it is, remove the faulty PCM and install the new
Service Precaution service PCM.
NOTE: To prevent possible electrostatic discharge The service PCM EEPROM will not be programmed.
damage to the PCM, do not touch the connector pins or DTC P0601 indicates the check sum error.
soldered components on the circuit board. Removal Procedure
Electrostatic Discharge (ESD) 2. Block the wheels.
Damage 3. Remove the two screws from the PCM electrical
Electronic components used in the control systems are connectors.
often designed to carry very low voltage. Electronic 4. Disconnect the PCM electrical connectors.
components are susceptible to damage caused by
electrostatic discharge. Less than 100 volts of static
electricity can cause damage to some electronic
components. By comparison, it takes as much as 4,000
volts for a person to even feel the zap of a static
discharge.
There are several ways for a person to become statically
charged. The most common methods of charging are by
friction and by induction. An example of charging by
friction is a person sliding across a car seat.
Charging by induction occurs when a person with well
insulated shoes stands near a highly charged object and
momentarily touches ground. Charges of the same
polarity are drained off leaving the person highly charged
with the opposite polarity. Static charges can cause
damage, therefore, it is important to use care when
handling and testing electronic components.
NOTE: To prevent possible Electrostatic Discharge
damage, follow these guidelines:
060RY00031
5. After removing the clip which fixes the PCM to the 2. Connect the PCM electrical connectors.
bracket, remove PCM. 3. Install the two screws to PCM electrical connectors.
060RY00026
060RY00031
1. Install the PCM to bracket and fix with the clip.
EEPROM
General Description
The Electronically Erasable Programmable Read Only
Memory (EEPROM) is a permanent memory that is
physically soldered within the PCM. The EEPROM
contains program and calibration information that the
PCM needs to control powertrain operation.
EEPROM Programming
1. Set-up – Ensure that the following conditions have
been met:
D The battery is fully charged.
D The ignition is “ON.”
D The Vehicle Interface Module cable connection at
the DLC is secure.
2. Program the PCM using the latest software matching
the vehicle. Refer to up-to-date Techline equipment
060RY00025
user’s instructions.
3. If the PCM fails to program, proceed as follows:
D Ensure that all PCM connections are OK.
D Check the Techline equipment for the latest
software version.
D Attempt to program the PCM. If the PCM still
cannot be programmed properly, replace the PCM.
Functional Check
1. Perform the On-Board Diagnostic System Check.
2. Start the engine and run for one minute.
3. Scan for DTCs using the Tech 2.
Throttle Position (TP) Sensor

Removal Procedure
2. Disconnect the TPS electrical connector.
3. Remove the bolts and the TP sensor from the throttle
body.
060RY00159
2. Connect the TP electrical connector.

3. Install the negative battery cable.
Vehicle Speed Sensor (VSS)

Removal Procedure
CAUTION: The VSS is located on the right side of
the transfer case just ahead of the rear propeller
shaft and very close to the exhaust pipes for 4WD
and on the extension cover for 2WD. Be sure that the
exhaust pipes are cool enough to touch before trying
to remove the VSS. If the pipes are hot, you could be
burned.
060RY00159
NOTE: Do not clean the TP sensor by soaking it in
2. Disconnect the VSS electrical connector.
solvent. The sensor will be damaged as a result.
Function Check
Use a Tech 2 to check the TP sensor output voltage at
closed throttle.
D The voltage should be under 0.85 volt.
D If the reading is greater than 0.85 volt, check the
throttle shaft to see if it is binding.
1. Install the TP sensor on the throttle body with the
bolts.
TS23748
3. Remove the bolt and the clamp securing the VSS in
place.
IMPORTANT: Have a container ready to catch any fluid
that leaks out when the VSS is removed from the transfer
case for 4WD and on the extension cover for 2WD.
TS23780
3. Connect the VSS electrical connector.
TS23780
4. Remove the VSS from the transfer case by wiggling it

slightly and pulling it straight out.
1. Inspect the electrical connector for signs of corrosion
or warping. Replace the VSS if the electrical
connector is corroded or warped.
2. Inspect the VSS driven gear for chips, breaks, or worn
condition. Replace the VSS if the driven gear is
chipped, broken or worn.
3. Inspect the O-ring for wear, nicks, tears, or
looseness. Replace the O-ring if necessary.
Installation Procedure 4. Check the transfer case oil level.

TS23748
Add fluid if
1. Install the VSS in the transfer case with the notch for necessary.
the connector facing the rear. 5. Connect the negative battery cable.
2. Secure the VSS in place with the clamp and the bolt.
Tighten
D Tighten the bolt to 16 N·m (12 lb ft.).
Air Cleaner/Air Filter Installation Procedure

1. Install the air cleaner housing in the vehicle with the
Removal Procedure retaining bolts.
2. Install the air filter element in the air cleaner housing.
1. Loosen the clamp between the air cleaner lid and the
mass air flow sensor. 3. Install the air cleaner lid on the MAF sensor and the air
cleaner housing.
025RY00001
2. Release the four latches securing the lid to the air 025RY00003
cleaner housing. Legend

3. Remove the air cleaner lid. (1) Air Cleaner Housing
4. Remove the air filter element. (2) Air Filter Element
5. Remove the retaining bolts and the air cleaner (3) Air Cleaner Lid
housing from the vehicle. (4) Mass Air Flow Sensor
4. Tighten the clamp and secure the four latches

between the lid and the air cleaner housing.
Common Chamber
Removal and Installation Procedure
Refer to Common Chamber in Engine Mechanical
section.
025RY00002
Legend
(1) Air Cleaner Housing
(2) Air Filter Element
(3) Air Cleaner Lid
Accelerator Pedal Replacement Installation Procedure

1. Install the accelerator pedal assembly on the
Removal Procedure bulkhead.
2. Install the two screws to the accelerator pedal
1. Disconnect the negative battery cable. assembly.
2. Disconnect the electrical harness from the
accelerator position sensor. Tighten
D Tighten the screws to 22 N·m (16 lb ft.).
101RY00006
101RY00007
Legend 3. Connect the electrical harness to the accelerator

(1) Accelerator Position Sensor position sensor.
(2) Accelerator Pedal Assembly
3. Remove the two screws from the accelerator pedal

assembly.
101RY00006
Legend
(1) Accelerator Position Sensor
101RY00007
4. Remove the accelerator pedal assembly from the

bulkhead. 4. Install the negative battery cable.
Fuel Filler Cap Fuel Filter

General Description Removal Procedure
The fuel filler cap includes a vacuum valve and a pressure 1. Disconnect the negative battery cable.
valve.
2. Remove the fuel filler cap.
If high vacuum or high pressure occurs in the fuel tank,
each valve works to adjust the pressure in order to
prevent damage of the tank.
041RW005
3. Disconnect the fuel line from the fuel filter on the

TS23767
engine side.
4. Disconnect the fuel line from the fuel filter on the fuel
tank side.
NOTE: Replace the fuel filler cap with the same type of
filler cap that was originally installed on the vehicle.
D Check the seal ring in the filler cap for any abnormality
and for seal condition.
D Replace the filler cap if any abnormality is found.
041RW006
5. Remove the bolt on the fuel filter holder. 3. Connect the fuel line on the engine side.
4. Connect the fuel line on the fuel tank side.
041RW007
6. Remove the fuel filter. 041RW006
5. Install the fuel filler cap.

1. Replace the fuel filter when the following occur:
D Fuel leaks from the fuel filter body.
D The fuel filter body is damaged.
D The fuel filter is clogged with dirt or sediment.
1. Install the fuel filter in the correct direction.
2. Install the bolt on the fuel filter holder.
Tighten
D Tighten the screws to 20 N·m (14 lb ft.).
041RW005
041RW007
Fuel Gauge Unit 5. Remove the fuel gauge unit retaining screws.
6. Remove the fuel gauge unit.
D Cover or plug the fuel tank to prevent dust, dirt, or
Removal Procedure debris from entering the tank.
2. Loosen the fuel filler cap.
3. Drain the fuel from the tank.
Tighten
D Tighten the drain plug to 20 N·m (14 lb ft.).
TS22911
1. Install the fuel gauge unit.
2. Install the fuel gauge unit retaining screws.
TS22907
4. Disconnect the wiring connector from the fuel gauge

unit.
TS22911
TS23771
3. Connect the wiring connector to the fuel gauge unit. 3. Remove the fuel rail. Refer to Fuel Rail section.
TS23771 014RW164
4. Fill the fuel tank with fuel. 4. Remove the injector retainer clip.
D Tighten the fuel filler cap.
D Check for leaks at the fuel gauge unit gasket.
Fuel Injectors
Removal Procedure
NOTE: If the fuel injectors are leaking, the engine oil may
be contaminated with fuel. Check the oil for signs of
contamination and change the oil and the filter if
necessary.
NOTE: Use care in removing the fuel injectors in order to
prevent damage to the fuel injector electrical connector
pins or the fuel injector nozzles. The fuel injector is an
electrical component and should not be immersed in any
type of cleaner as this may damage the fuel injector.
055RW009
IMPORTANT: Fuel injectors are serviced as a complete
5. Remove the fuel injector assembly.
assembly only.
6. Remove the O-ring from the fuel injector.
7. Remove the O-ring backup from the fuel injector .
2. Remove the common chamber. Refer to Common
Chamber in Engine Mechanical section.
1. Inspect the O-rings for cracks or leaks.
2. Replace worn or damaged O-rings.
3. Lubricate the new O-rings with engine oil before
installation.
Installation Procedure Fuel Metering System

1. Install the O-ring backup on the fuel injector.
2. Install the new O-ring on the fuel injector. Fuel Pressure Relief Procedure
3. Install the fuel injector on the fuel rail. CAUTION: To reduce the risk of fire and personal
injury, there are necessary to relieve the fuel system
pressure filler and gauge unit before servicing the
fuel system components.
CAUTION: After relieving the system pressure, a
small amount of fuel may be released when servicing
fuel lines or connections. Reduce the chance of
personal injury by covering the fuel line fittings with
a shop towel before you disconnect the fittings. The
towels will absorb any fuel that may leak out. When
the disconnect is completed, place the towel in an
approved container.
2. Remove the fuel pump relay from the underhood
relay box. Refer to Fuel Pump Relay section.
055RW009
4. Use new fuel injector retainer clips to retain the fuel

injector to the fuel rail.
5. Coat the end of the fuel injector with gasoline.
6. Install the fuel rail. Refer to Fuel Rail section.
TS23976R
3. Start the engine and allow it to stall.

4. Crank the engine for 30 seconds.
014RW164
7. Install the common chamber. Refer to Common

Chamber in Engine Mechanical section.
8. Install the engine cover.
Fuel Pump Assembly 4. Fill the tank with fuel.

5. Tighten the fuel filler cap.
Removal Procedure
2. Drain all the fuel from the tank.
3. Install and tighten the drain plug.
Tighten
4. Remove the fuel tank. Refer to Fuel Tank section.
5. Remove the retaining screws from the fuel tank.
6. Remove the fuel pump assembly from the fuel tank.
D Cover the fuel pump opening in order to prevent
dust, dirt, or debris from entering the fuel tank.
TS23795
Fuel Pump Relay

Removal Procedure
1. Remove the fuse and relay box cover from under the
hood.
2. Consult the diagram on the cover to determine which
is the correct relay.
3. Insert a small screwdriver into the catch slot on the
forward side of the fuel pump relay.
D The screwdriver blade will release the catch inside.
TS23795
1. Inspect the fuel pump gasket for tears, cracks,
stretching, or rotting. If any of these conditions are
found, replace the fuel pump gasket.
2. Inspect the in-tank fuel filter for tears or evidence of
dirt, debris, or water in the fuel. If any of these
conditions are found, replace the in-tank fuel filter.
1. Install the fuel pump assembly.
Tighten
D Tighten the fuel pump assembly mounting
bolts to 3 N·m (27 lb ft.).
2. Install the fuel pump assembly retaining screws.
3. Install the fuel tank assembly. Refer to Fuel Tank
section.
D08RY00292
4. Pull the relay straight up and out of the fuse and relay Fuel Rail Assembly
box.
Removal Procedure
NOTE:
D Do not attempt to remove the fuel inlet fitting on the
fuel rail. It is staked in place. Removing the fuel inlet
fitting will result in damage to the fuel rail or the
internal O-ring seal.
D Use care when removing the fuel rail assembly in
order to prevent damage to the injector electrical
connector terminals and the injector spray tips.
D Fittings should be capped and holes plugged during
servicing to prevent dirt and other contaminants from
entering open lines and passages.
IMPORTANT: An eight-digit identification number is
stamped on the side of the fuel rail. Refer to this number
when you service the fuel rail or when a replacement part
is required.
TS23976R
1. Insert the relay into the correct place in the fuse and
relay box with the catch slot facing forward.
2. Press down until the catch engages.
D An audible “click” will be heard.
014RY00008
Before removal, the fuel rail assembly may be cleaned

with a spray type engine cleaner. Follow the spray
package instructions. Do not immerse the fuel rails in
liquid cleaning solvent.
1. Depressurize the fuel system. Refer to Fuel Pressure
Relief Procedure in this Section.
3. Remove the engine cover.
TS23976R
3. Install the fuse and relay box cover. 4. Disconnect the throttle position sensor electrical
connector from throttle body.
5. Disconnect the connectors from manifold absolute
pressure sensor, solenoid valve, electric vacuum
sensing valve.
6. Disconnect the vacuum hose on canister VSV and
positive crankcase ventilation hose.
7. Remove the common chamber. Refer to the common 4. Connect the vacuum hose on Canister VSV and
chamber in Engine Mechanical section. positive crankcase ventilation hose.
1. Lift up carefully on the fuel injectors. Do not 5. Connect the connectors to manifold absolute
separate the fuel injectors from the fuel rail. pressure sensor, solenoid valve, electric vacuum
2. If an injector becomes separated from the fuel sensing valve.
rail, the infector O-ring seals and the retainer clip 6. Connect the throttle position sensor electrical
must be replaced. connector to throttle body.
3. Drain residual fuel into an approved container. 7. Install the engine cover.
9. Crank the engine until it starts. Cranking the engine
may take longer than usual due to trapped air in the
fuel rail and in the injectors.
Fuel Tank
Removal Procedure
2. Loosen the fuel filler cap.
3. Drain the fuel from the tank into an approved
container.
4. Install and tighten the drain plug.
Tighten
5. Disconnect the fuel filler hose at the fuel tank.
014RW164 6. Disconnect the air breather hose at the fuel tank.
8. If removal of the fuel pressure regulator is necessary,
refer to Fuel Pressure Regulator section.
9. If removal of the fuel injectors is necessary, refer to
Fuel Injectors section.
1. If the fuel injectors were removed, install them. Refer
to Fuel Injectors section.
2. If the fuel pressure regulator was removed, install it.
Refer to Fuel Pressure Regulator section.
3. Install the common chamber. Refer to common
chamber in engine Mechanical section.
TS23796
7. Remove the undercover retaining bolts.
014RW164
8. Remove the undercover. 16. Remove the fuel tank.
TS23797 TS23770
9. Disconnect the wiring connector to the fuel pump.

10. Disconnect the wiring connector to the fuel gauge Installation Procedure
unit.
1. Install the fuel tank.
11. Remove the fuel gauge unit connector from the
bracket. D Place the flanges on the left and right side of the
tank on the bracket.
12. Disconnect the EVAP vapor hose.
2. Install the fuel tank retaining bolts.
13. Disconnect the fuel supply hose.
14. Disconnect the fuel return hose. Tighten
D Tighten the fuel tank retaining bolts to 36 N·m
D Plug the hoses to prevent dust from entering the
hoses. (27 lb ft.).
TS23770
TS23769
3. Connect the fuel return hose.
15. Remove the fuel tank retaining bolts on both sides.
4. Connect the fuel supply hose.
5. Connect the EVAP vapor hose.
6. Connect the wiring connector for the fuel gauge unit.
7. Connect the fuel gauge wiring connector to the
bracket.
8. Connect the wiring connector for the fuel pump. 12. Connect the air breather hose at the tank.
TS23769 TS23796
9. Install the undercover. 13. Fill the fuel tank with fuel.
10. Secure the undercover with the retaining bolts. 14. Tighten the fuel filler cap.
Torque: 36 N·m (26 Ib in) 15. Connect the negative battery cable.
Throttle Body (TB)

Removal Procedure
2. Drain the cooling system. Refer to Cooling System
section.
3. Disconnect the electrical connectors:
D Throttle position (TP) sensor.
D Intake air temperature (IAT) sensor. Refer to Intake
Air Temperature Sensor section.
TS23797
11. Connect the fuel filler fuse at the tank.
060RY00014
4. Disconnect the vacuum hose below the air horn. Tighten
5. Remove the intake air duct clamp. D Tighten the throttle body mounting bolts to 10
6. Disconnect the intake air duct. N·m (87 lb in).
7. Disconnect the coolant lines from the throttle body.
8. Remove the bolts from the common chamber.
9. Remove the throttle body from the common chamber.
10. Remove the gasket from the common chamber.
025RY00004
5. Install the coolant lines.

6. Connect all the vacuum lines.
7. Install the intake air duct.
8. Tighten the intake air duct clamp.
025RY00004
11. Remove the TP sensor. Refer to Throttle Position 9. Connect all the electrical connectors:
(TP) Sensor section. D Throttle position (TP) sensor.
D Intake air temperature (IAT) sensor. Refer to Intake
Inspection Procedure Air Temperature Sensor section.
NOTE: Do not use solvent of any type when you clean the
gasket surfaces on the intake manifold and the throttle
body assembly. The gasket surfaces and the throttle
body assembly may be damaged as a result.
D If the throttle body gasket needs to be replaced,
remove any gasket material that may be stuck to the
mating surfaces of the manifold.
D Do not leave any scratches in the aluminum casting.
1. Install the TP sensor. Refer to Throttle Position (TP)
Sensor section.
2. Install the gasket on the common chamber.
3. Install the throttle body on the common chamber.
4. Secure the gasket and the throttle body with the four
bolts.
D The vacuum lines must be properly routed under 060RY00020
the throttle body before tightening the mounting 10. Install the accelerator cable assembly. Refer to
bolts. Accelerator Cable in Engine Speed Control System
section.
11. Fill the cooling system. Refer to Cooling System
section.
12. Install the negative battery cable.
Electronic Ignition System CAUTION: Ignition coil assembly #6 is different

from ignition coil assembly from #1 to #5. Ignition
coil assemblies #6 is short type. So, note it when
Removal Procedure installing ignition coil assembly of #6.
2. Disconnect the ignition coil connector at the ignition
coil assemblies.
3. Remove the two screws that secure the ignition coil
assemblies to the rocker cover.
060RY00002
Legend
(1) Long Type Ignition Coil Assemblies (#1 ∼ #5)
(2) Short Type Ignition Coil Assembly (#6)
3. Install ignition coil assemblies and tighten the fixing

060RY022
bolts to the specified torque.
Legend
Torque: 4 N·m (35.4 Ib in)
(1) Ignition Coil Connectors
(2) Bolts
(3) Ignition Coil Assemblies
4. Remove the ignition coil assemblies and the spark

plug boot from the spark plug.
D Twist the ignition coil assemblies while pulling it
straight up.
5. Use the approhiate spark plug socket in order to
remove the spark plug from the engine.
NOTE: The plug must thread smoothly into the cylinder
head and be fully seated. Use a thread chaser if
necessary to clean the threads in the cylinder head.
Cross-threading or failure to fully seat the spark plug can
cause plug overheating, exhaust blow-by gases, or
thread damage. Do not overtighten the spark plugs. Over
tightening can cause aluminum threads to strip. 060RY022
1. Install the spark plug in the engine. Use the Legend

appropriate spark plug socket. (1) Ignition Coil Connectors
Tighten (2) Bolts
D Tighten the spark plug to 18 N·m (13 lb ft.). (3) Ignition Coil Assemblies
2. Install the ignition coil assemblies and spark plug boot
over the spark plug. 4. Connect the ignition coil connector at the ignition coil
assemblies.
Catalytic Converter Installation Procedure

1. Insert the relay into the correct place in the fuse and
Removal and Installation Procedure relay box with the catch slot facing forward.
Refer to Engine Exhaust in Engine section. 2. Press down until the catch engages.
D An audible “click” will be heard.
3. Install the fuse and relay box cover.
Air Conditioning Thermo Relay
Removal Procedure
1. Remove the fuse and relay box cover from under the
hood.
2. Consult the diagram on the cover to determine which
is the correct relay.
3. Insert a small screwdriver into the catch slot on the
forward side of the fuel pump relay.
D The screwdriver blade will release the catch inside.
TS23986
EVAP Canister Hoses

Service Information
To view the routing of the EVAP canister hoses, refer to
Vehicle Emission Control Information in Diagnosis
section.
D08RW131
4. Pull the relay straight up and out of the fuse and relay
box.
TS23986
EVAP Canister 4. Remove the retaining two bolts on the mounting

bracket and slide the canister out of mounting
bracket.
Removal Procedure
2. Disconnect the three hoses from the EVAP canister.
014RW146
014RW145 1. Inspect the hoses for cracks and leaks.
3. Disconnect the fuel vapor connector and the purge 2. Inspect the canister for a damaged case.
hose from the EVAP canister vent solenoid.
1. Slide the canister into mounting bracket and install
the mounting bracket two bolts.
014RW147
014RW146
2. Connect the fuel vapor connector to the EVAP 3. Disconnect the connector and hose.
canister vent solenoid.
3. Connect the three hoses to the EVAP canister.
014RW148
014RW145 Inspection Procedure

1. Check for cracks or leaks.
2. Energize the solenoid and try to blow through it. The
EVAP Canister Vent Solenoid solenoid should not allow passage of air when
energized. (J 35616 Connector Test Kit can be used
to easily attach jumper wires from the battery to the
Removal Procedure solenoid).
2. Slide out the EVAP canister vent solenoid from Installation Procedure
mounting bracket.
1. Connect the connector and hose.
014RW149
014RW148
2. Slide the EVAP canister vent solenoid into mounting EVAP Canister Purge Solenoid
bracket.
Removal Procedure
1. Disconnect the electrical connector from the EVAP
canister purge solenoid.
2. Disconnect the vacuum hoses from the EVAP
canister purge solenoid.
014RW149
Fuel Tank Pressure Sensor

Removal Procedure 014RW136
1. Remove the fuel pump assembly. Refer to Fuel Tank 3. Remove the EVAP canister purge solenoid retaining
In Fuel Pump section. bolt from the common chamber.
2. Carefully pry the fuel tank pressure sensor out of the 4. Remove the EVAP canister purge solenoid.
top of the fuel pump assembly.
1. Inspect the vapor pressure sensor for cracks in the
housing and corrosion on the electrical terminals.
2. Inspect the rubber grommet for tears and signs of rot.
1. Install the rubber grommet on the fuel pump
assembly.
2. Install the fuel tank vapor pressure sensor on the fuel
pump assembly.
D Insert the sensor nipple firmly into the grommet.
D Keep twisting and pushing the sensor until the wide
portion of the nipple shows on the other side of the
grommet.
3. Install the fuel pump assembly on the fuel tank. Refer 014RW137
to Fuel Tank In Fuel Pump section.

Installation Procedure Linear Exhaust Gas

1. Install the EVAP canister purge solenoid on the upper Recirculation (EGR) Valve
intake manifold.
2. Install the EVAP canister purge solenoid retaining
bolt.
Removal Procedure
Tighten 1. Disconnect the negative battery cable.
D Tighten the bolts to 20 N·m (16 lb ft.). 2. Disconnect the electrical connector at the EGR valve.
3. Connect the vacuum hoses to the EVAP canister
purge solenoid.
014RW139
3. Remove the bolts from the common chamber.

014RW137
4. Connect the electrical connector to the EVAP canister

purge solenoid.
014RW098
4. Remove the EGR valve from the common chamber

manifold.
014RW138 5. Remove the gasket from the common chamber
manifold.
Fuel Tank Vent Valve
Removal and Installation Procedure
Refer to Fuel Pump section.
Installation Procedure Positive Crankcase Ventilation

1. Install the gasket on the common chamber. (PCV) Valve
2. Install the EGR valve on the common chamber.
3. Secure the EGR valve and the gasket with the bolts. Removal Procedure
Torque: 25 N·m (18 Ib ft)
1. Remove the vacuum hose at the PCV valve.
NOTE: It is possible to install the EGR valve rotated 180° D Slide the clamp back to release the hose.
from the correct position. Make sure that the base of the 2. Pull the PCV valve from the rubber grommet in the
valve is placed so that it aligns with the mounting flange. right valve cover.
014RW098
014RW097
4. Connect the electrical connector at the EGR valve.

Before inspecting the PCV valve, make sure that the
hoses are connected properly and are in good condition.
Also check that the oil pan and rocker cover gaskets are
sealing properly.
PCV Valve
2. Disconnect the valve from the rocker cover.
RESULT: A hissing noise should be heard from the
valve. If no noise is heard, the PCV valve or hose is
plugged.
3. Remove the PCV valve from the engine.
a. Blow air into the rocker cover side of the valve.
RESULT: Air should pass freely.
b. Blow air into the air cleaner side of the valve.
RESULT: Air should not pass through the valve.
014RW139 4. Re-install the PCV valve and remove the oil filler cap.
5. Connect the negative battery cable. RESULT: A small vacuum should be felt at the oil filler
hole.
Installation Procedure connectors. Merely wiggling a connector on a sensor, or

in the wiring harness, may temporarily correct the open
1. Push the PCV valve into the rubber grommet in the circuit. Intermittent problems may also be caused by
left valve cover. oxidized or loose connections.
2. Install the vacuum hose on the PCV valve and secure Be certain of the type of connector/terminal before
the vacuum hose with the clamp. making any connector or terminal repair. Weather-Pack
and Com-Pack III terminals look similar, but are serviced
differently.
PCM Connectors and Terminals

Removal Procedure
1. Remove the connector terminal retainer.
2. Push the wire connected to the affected terminal
through the connector face so that the terminal is
exposed.
3. Service the terminal as necessary.
1. Bend the tab on the connector to allow the terminal to
be pulled into position within the connector.
2. Pull carefully on the wire to install the connector
014RW097 terminal retainer.
Wiring and Connectors Wire Harness Repair: Twisted

Shielded Cable
Wiring Harness Service
The control module harness electrically connects the Removal Procedure
control module to the various solenoids, switches and
sensors in the vehicle engine compartment and 1. Remove the outer jacket.
passenger compartment. 2. Unwrap the aluminum/mylar tape. Do not remove the
Replace wire harnesses with the proper part number mylar.
replacement.
Because of the low amperage and voltage levels utilized
in powertrain control systems, it is essential that all wiring
in environmentally exposed areas be repaired with crimp
and seal splice sleeves.
The following wire harness repair information is intended
as a general guideline only. Refer to Chassis Electrical
section for all wire harness repair procedures.
Connectors and Terminals

Use care when probing a connector and when replacing
terminals. It is possible to short between opposite
terminals. Damage to components could result. Always
use jumper wires between connectors for circuit
checking. NEVER probe through Weather-Pack seals.
Use an appropriate connector test adapter kit which
contains an assortment of flexible connectors used to
probe terminals during diagnosis. Use an appropriate
fuse remover and test tool for removing a fuse and to
adapt the fuse holder to a meter for diagnosis. 047
Open circuits are often difficult to locate by sight because 3. Untwist the conductors.
oxidation or terminal misalignment are hidden by the
4. Strip the insulation as necessary. 4. Tape over the whole bundle to secure.
048 050
Installation Procedure Twisted Leads

1. Splice the wires using splice clips and rosin core
solder. Removal Procedure
2. Wrap each splice to insulate.
1. Locate the damaged wire.
3. Wrap the splice with mylar and with the drain
(uninsulated) wire. 2. Remove the insulation as required.
051
049
Installation Procedure 3. Twist the wires as they were before starting this
procedure.
1. Use splice clips and rosin core solder in order to splice
the two wires together.
054
4. Tape the wires with electrical tape. Hold in place.

052
2. Cover the splice with tape in order to insulate it from

the other wires.
055
053
Weather-Pack Connector 3. Cut the wire immediately behind the cable seal.
Tools Required
J 28742-A Weather-Pack II Terminal Remover
Removal Procedure
A Weather-Pack connector can be identified by a rubber
seal at the rear of the connector. This engine room
connector protects against moisture and dirt, which could
from oxidation and deposits on the terminals. This
protection is important, because of the low voltage and
the low amperage found in the electronic systems.
1. Open the secondary lock hinge on the connector.
072
Make certain the connectors are properly seated and all
of the sealing rings are in place when you reconnect the
leads. The secondary lock hinge provides a backup
locking feature for the connector. The secondary lock
hinge is used for added reliability. This flap should retain
the terminals even if the small terminal lock tangs are not
positioned properly.
Do not replace the Weather-Pack connections with
standard connections. Read the instructions provided
with the Weather-Pack connector and terminal packages.
1. Replace the terminal.
070
2. Use tool J 28742-A or the equivalent to remove the 2. Slip the new seal onto the wire.
pin and the sleeve terminals. Push on J 28742-A to 3. Strip 5 mm (0.2”) of insulation from the wire.
release. 4. Crimp the terminal over the wire and the seal.
NOTE: Do the use an ordinary pick or the terminal may
be bent or deformed. Unlike standard blade terminals,
these terminals cannot be straightened after they have
been improperly bent.
073
071
5. Push the terminal and the connector to engage the 2. Insert the J 35689 tool or equivalent (3) in order to
locking tangs. release the terminal locking tang (2).
070 060
6. Close the secondary locking hinge. 3. Push the wire and the terminal out through the
connector. If you reuse the terminal, reshape the
locking tang.
Com-Pack III
General Information Metri-Pack terminals are also referred to as “pull-to-seat”
The Com-Pack III terminal looks similar to some terminals.
Weather-Pack terminals. This terminal is not sealed and 1. In order to install a terminal on a wire, the wire must be
is used where resistance to the environment is not inserted through the seal (2) and through the
required. Use the standard method when repairing a connector (3).
terminal. Do not use the Weather-Pack terminal tool J
28742-A or equivalent. These will damage the terminals. 2. The terminal (1) is then crimped onto the wire.
Metri-Pack
Tools Required
J 35689 Terminal Remover
Removal Procedure
Some connectors use terminals called Metri-Pack Series
150. These may be used at the engine coolant
temperature (ECT) sensor.
1. Slide the seal (1) back on the wire.
061
3. Then the terminal is pulled back into the connector to

seat it in place.
General Description (PCM and uses the CMP signal to indicate the position of the #1
piston during its power stroke. This allows the PCM to
Sensors) calculate true sequential fuel injection (SFI) mode of
operation. If the PCM detects an incorrect CMP signal
58X Reference PCM Input while the engine is running, DTC P0341 will set. If the
The powertrain control module (PCM) uses this signal CMP signal is lost while the engine is running, the fuel
from the crankshaft position (CKP) sensor to calculate injection system will shift to a calculated sequential fuel
engine RPM and crankshaft position at all engine speeds. injection mode based on the last fuel injection pulse, and
The PCM also uses the pulses on this circuit to initiate the engine will continue to run. As long as the fault is
injector pulses. If the PCM receives no pulses on this present, the engine can be restarted. It will run in the
circuit, DTC P0337 will set. The engine will not start and calculated sequential mode with a 1-in-6 chance of the
run without using the 58X reference signal. injector sequence being correct.
Refer to DTC P0341 for further information.
A/C Request Signal
This signal tells the PCM when the A/C mode is selected
at the A/C control head. The PCM uses this to adjust the
idle speed before turning “ON” the A/C clutch. The A/C
compressor will be inoperative if this signal is not
available to the PCM.
Refer to A/C Clutch Circuit Diagnosis section for A/C
wiring diagrams and diagnosis for the A/C electrical
system.
Crankshaft Position (CKP) Sensor

The crankshaft position (CKP) sensor provides a signal
used by the powertrain control module (PCM) to calculate
the ignition sequence. The CKP sensor initiates the 58X
reference pulses which the PCM uses to calculate RPM
and crankshaft position.
Refer to Electronic Ignition System section for additional
information.
0014
Engine Coolant Temperature (ECT) Sensor

The engine coolant temperature (ECT) sensor is a
thermistor (a resistor which changes value based on
temperature) mounted in the engine coolant stream. Low
coolant temperature produces a high resistance of
100,000 ohms at –40°C (–40°F). High temperature
causes a low resistance of 70 ohms at 130°C (266°F).
The PCM supplies a 5-volt signal to the ECT sensor
through resistors in the PCM and measures the voltage.
The signal voltage will be high when the engine is cold and
low when the engine is hot. By measuring the voltage, the
PCM calculates the engine coolant temperature. Engine
coolant temperature affects most of the systems that the
PCM controls.
The Tech 2 displays engine coolant temperature in
degrees. After engine start-up, the temperature should
0013 rise steadily to about 85°C (185°F). It then stabilizes
when the thermostat opens. If the engine has not been
Camshaft Position (CMP) Sensor and run for several hours (overnight), the engine coolant
Signal temperature and intake air temperature displays should
The camshaft position (CMP) sensor sends a CMP signal be close to each other. A hard fault in the engine coolant
to the PCM. The PCM uses this signal as a “sync pulse” to sensor circuit will set DTC P0177 or DTC P0118. An
trigger the injectors in the proper sequence. The PCM intermittent fault will set a DTC P1114 or P1115.
detect HO2S response problems. If the response time of
an HO2S is determined to be too slow, the PCM will store
a DTC that indicates degraded HO2S performance.
0016
Electrically Erasable Programmable Read

Only Memory (EEPROM) 060RY00030
The electrically erasable programmable read only

memory (EEPROM) is a permanent memory chip that is Catalyst Monitor Heated Oxygen Sensors
physically soldered within the PCM. The EEPROM Three-way catalytic converters are used to control
contains the program and the calibration information that emissions of hydrocarbons (HC), carbon monoxide (CO),
the PCM needs to control powertrain operation. and oxides of nitrogen (NOx). The catalyst within the
Unlike the PROM used in past applications, the EEPROM converters promotes a chemical reaction. This reaction
is not replaceable. If the PCM is replaced, the new PCM oxidizes the HC and CO present in the exhaust gas and
will need to be programmed. Equipment containing the converts them into harmless water vapor and carbon
correct program and calibration for the vehicle is required dioxide. The catalyst also reduces NOx by converting it to
to program the PCM. nitrogen. The PCM can monitor this process using the
Bank 1 HO2S 2 and the Bank 2 HO2S 2 heated oxygen
Fuel Control Heated Oxygen Sensors sensors. The Bank 1 HO2S 1 and the Bank 2 HO2S 1
The fuel control heated oxygen sensors (Bank 1 HO2S 1 sensors produce an output signal which indicates the
and Bank 2 HO2S 1) are mounted in the exhaust stream amount of oxygen present in the exhaust gas entering the
where they can monitor the oxygen content of the exhaust three-way catalytic converter. The Bank 1 HO2S 2 and
gas. The oxygen present in the exhaust gas reacts with the Bank 2 HO2S 2 sensors produce an output signal
the sensor to produce a voltage output. This voltage which indicates the oxygen storage capacity of the
should constantly fluctuate from approximately 100 mV to catalyst. This indicates the catalyst’s ability to efficiently
900 mV. The heated oxygen sensor voltage can be convert exhaust gases. If the catalyst is operating
monitored with a Tech 2. By monitoring the voltage output efficiently, the Bank 1 HO2S 1 and the Bank 2 HO2S 1
of the oxygen sensor, the PCM calculates the pulse width signals will be more active than the signals produced by
command for the injectors to produce the proper the Bank 1 HO2S 2 and the Bank 2 HO2S 2 sensors.
combustion chamber mixture. The catalyst monitor sensors operate the same as the
D Low HO2S voltage is a lean mixture which will result in fuel control sensors. The Bank 1 HO2S 2 and the Bank 2
a rich command to compensate. HO2S 2 sensors’ main function is catalyst monitoring, but
D High HO2S voltage is a rich mixture which will result in they also have a limited role in fuel control. If a sensor
a lean command to compensate. output indicates a voltage either above or below the 450
An open Bank 1 HO2S 1 signal circuit will set a DTC mV bias voltage for an extended period of time, the PCM
P0134 and the Tech 2 will display a constant voltage will make a slight adjustment to fuel trim to ensure that
between 400-500 mV. A constant voltage below 300 mV fuel delivery is correct for catalyst monitoring.
in the sensor circuit (circuit grounded) will set DTC A problem with the Bank 1 HO2S 2 signal circuit will set
P0131. A constant voltage above 800 mV in the circuit will DTC P0137, P0138, or P0140, depending on the specific
set DTC P0132. Faults in the Bank 2 HO2S 1 signal condition. A problem with the Bank 2 HO2S 2 signal
circuit will cause DTC 0154 (open circuit), DTC P0151 circuit will set DTC P0157, P0158, or P0160, depending
(grounded circuit), or DTC P0152 (signal voltage high) to on the specific condition. A fault in the heated oxygen
set. A fault in the Bank 1 HO2S 1 heater circuit will cause sensor heater element or its ignition feed or ground will
DTC P0135 to set. A fault in the Bank 2 HO2S 1 heater result in lower sensor response. This may cause
circuit will cause DTC P0155 to set. The PCM can also incorrect catalyst monitor diagnostic results.
The Tech 2 displays the temperature of the air entering
the engine. The temperature should read close to the
ambient air temperature when the engine is cold and rise
as underhood temperature increases. If the engine has
not been run for several hours (overnight), the IAT sensor
temperature and engine coolant temperature should read
close to each other. A fault in the IAT sensor circuit will set
DTC P0112 or DTC P0113.
Linear Exhaust Gas Recirculation (EGR)

Control
The PCM monitors the exhaust gas recirculation (EGR)
actual position and adjusts the pintle position accordingly.
The PCM uses information from the following sensors to
control the pintle position:
D Engine coolant temperature (ECT) sensor.
D Mass air flow (MAF) sensor.
TS24067
Mass Air Flow (MAF) Sensor

The mass air flow (MAF) sensor measures the difference
between the volume and the quantity of air that enters the
engine. “Volume” means the size of the space to be filled.
“Quantity” means the number of air molecules that will fit
into the space. This information is important to the PCM
because heavier, denser air will hold more fuel than
lighter, thinner air. The PCM adjusts the air/fuel ratio as
needed depending on the MAF value. The Tech 2 reads
the MAF value and displays it in terms of grams per
second (gm/s). At idle, the Tech 2 should read between
4-7 gm/s on a fully warmed up engine. Values should
change quickly on acceleration. Values should remain
stable at any given RPM. A failure in the MAF sensor or
circuit will set DTC P0101, DTC P0102, or DTC P0103.
TS23365A
Legend
(1) Bank 1 Sensor 1 (Fuel Control)
(2) Catalytic Converter
(3) Bank 1 Sensor 2 (Catalyst Monitor)
(4) Bank 2 Sensor 1 (Fuel Control)
(5) Bank 2 Sensor 2 (Catalyst Monitor)
Intake Air Temperature (IAT) Sensor

The intake air temperature (IAT) sensor is a thermistor
which changes its resistance based on the temperature of
air entering the engine. Low temperature produces a high
resistance of 100,000 ohms at –40°C (–40°F). High
temperature causes low resistance of 70 ohms at 130°C
(266°F) . The PCM supplies a 5-volt signal to the sensor 0007
through a resistor in the PCM and monitors the signal Manifold Absolute Pressure (MAP) Sensor
voltage. The voltage will be high when the incoming air is
cold. The voltage will be low when the incoming air is hot. The manifold absolute pressure (MAP) sensor responds
By measuring the voltage, the PCM calculates the to changes in intake manifold pressure (vacuum). The
incoming air temperature. The IAT sensor signal is used MAP sensor signal voltage to the PCM varies from below
to adjust spark timing according to the incoming air 2 volts at idle (high vacuum) to above 4 volts with the
density.
ignition ON, engine not running or at wide-open throttle an accurate reading because its resistance is too low.
(low vacuum). Therefore, a digital voltmeter with at least 10 megohms
The MAP sensor is used to determine the following: input impedance is required to ensure accurate voltage
D Manifold pressure changes while the linear EGR flow readings. Tool J 39200 meets this requirement. The PCM
test diagnostic is being run. Refer to DTC P0401. controls output circuits such as the injectors, fan relays,
D Engine vacuum level for other diagnostics. etc., by controlling the ground or the power feed circuit
through transistors or through either of the following two
D Barometric pressure (BARO).
devices:
If the PCM detects a voltage that is lower than the
D Output Driver Module (ODM)
possible range of the MAP sensor, DTC P0107 will be set.
A signal voltage higher than the possible range of the D Quad Driver Module (QDM)
sensor will set DTC P0108. An intermittent low or high
voltage will set DTC P1107, respectively. The PCM can
detect a shifted MAP sensor. The PCM compares the
MAP sensor signal to a calculated MAP based on throttle
position and various engine load factors. If the PCM
detects a MAP signal that varies excessively above or
below the calculated value, DTC P0106 will set.
060RY00019
PCM Components
The PCM is designed to maintain exhaust emission levels
to government mandated standards while providing
excellent driveability and fuel efficiency. The PCM
monitors numerous engine and vehicle functions via
055RW004
electronic sensors such as the throttle position (TP)
sensor, heated oxygen sensor (HO2S), and vehicle
Powertrain Control Module (PCM) speed sensor (VSS). The PCM also controls certain
The powertrain control module (PCM) is located in the engine operations through the following:
passenger compartment below the center console. The D Fuel injector control
PCM controls the following: D Ignition control module
D Fuel metering system. D ION sensing module
D Transmission shifting (automatic transmission only). D Automatic transmission shift functions
D Ignition timing. D Cruise control
D On-board diagnostics for powertrain functions. D Evaporative emission (EVAP) purge
The PCM constantly observes the information from D A/C clutch control
various sensors. The PCM controls the systems that
affect vehicle performance. The PCM performs the PCM Voltage Description
diagnostic function of the system. It can recognize
operational problems, alert the driver through the MIL The PCM supplies a buffered voltage to various switches
(Check Engine lamp), and store diagnostic trouble codes and sensors. It can do this because resistance in the
(DTCs). DTCs identify the problem areas to aid the PCM is so high in value that a test light may not illuminate
technician in making repairs. when connected to the circuit. An ordinary shop
voltmeter may not give an accurate reading because the
PCM Function voltmeter input impedance is too low. Use a 10-megohm
input impedance digital voltmeter (such as J 39200) to
The PCM supplies either 5 or 12 volts to power various
assure accurate voltage readings.
sensors or switches. The power is supplied through
The input/output devices in the PCM include
resistances in the PCM which are so high in value that a
analog-to-digital converters, signal buffers, counters,
test light will not light when connected to the circuit. In
and special drivers. The PCM controls most components
some cases, even an ordinary shop voltmeter will not give
with electronic switches which complete a ground circuit
when turned “ON.” These switches are arranged in Throttle Position (TP) Sensor
groups of 4 and 7, called either a surface-mounted quad The throttle position (TP) sensor is a potentiometer
driver module (QDM), which can independently control up connected to the throttle shaft on the throttle body. The
to 4 output terminals, or QDMs which can independently PCM monitors the voltage on the signal line and
control up to 7 outputs. Not all outputs are always used. calculates throttle position. As the throttle valve angle is
changed (accelerator pedal moved), the TP sensor signal
PCM Input/Outputs also changes. At a closed throttle position, the output of
Inputs – Operating Conditions Read the TP sensor is low. As the throttle valve opens, the
D Air Conditioning “ON” or “OFF” output increases so that at wide open throttle (WOT), the
output voltage should be above 4 volts.
D Engine Coolant Temperature
The PCM calculates fuel delivery based on throttle valve
D Crankshaft Position angle (driver demand). A broken or loose TP sensor may
D Exhaust Oxygen Content cause intermittent bursts of fuel from an injector and
D Electronic Ignition unstable idle because the PCM thinks the throttle is
D Manifold Absolute Pressure moving.
D Battery Voltage
D Throttle Position
D Vehicle Speed
D Fuel Pump Voltage
D Power Steering Pressure
D Intake Air Temperature
D Mass Air Flow
D Engine Knock
D Camshaft Position
Outputs – Systems Controlled
D EVAP Canister Purge
D Exhaust Gas Recirculation (EGR)
D Ignition Control
D Fuel Control
D ION Sensing Module
D Electric Fuel Pump 060RY00027
D Air Conditioning
Transmission Fluid Temperature (TFT)
D Diagnostics
Sensor
– Malfunction Indicator Lamp
The transmission fluid temperature sensor is a thermistor
– Data Link Connector (DLC) which changes its resistance based on the temperature of
– Data Output the transmission fluid. For a complete description of the
D Transmission Control Module TFT sensor, refer to 4L30-E Automatic Transmission
Diagnosis section.
PCM Service Precautions A failure in the TFT sensor or associated wiring will cause
The PCM is designed to withstand normal current draws DTC P0712 or DTC P0713 to set. In this case, engine
associated with vehicle operation. Avoid overloading any coolant temperature will be substituted for the TFT
circuit. When testing for opens and shorts, do not ground sensor value and the transmission will operate normally.
or apply voltage to any of the PCM’s circuits unless
instructed to do so. These circuits should only be tested Transmission Range Switch
using digital voltmeter J 39200. The PCM should remain IMPORTANT: The vehicle should not be driven with the
connected to the PCM or to a recommended breakout transmission range switch disconnected; idle quality will
box. be affected.
The four inputs from the transmission range switch
Reprogramming The PCM indicate to the PCM which position is selected by the
Reprogramming of the PCM is done without removing it transmission selector lever. This information is used for
from the vehicle . This provides a flexible and ignition timing, EVAP canister purge, EGR operation.
cost-effective method of making changes in software For more information on the transmission on the
calibrations. transmission range switch, refer to 4L30-E Automatic
Refer to the latest Techline information on Transmission section.
reprogramming or flashing procedures.
Vehicle Speed Sensor (VSS) components are susceptible to damage caused by
The PCM determines the speed of the vehicle by electrostatic discharge. Less than 100 volts of static
converting a plusing voltage signal from the vehicle speed electricity can cause damage to some electronic
sensor (VSS) into miles per hour. The PCM uses this components. By comparison, it takes as much as 4000
signal to operate the cruise control, speedometer, and the volts for a person to feel even the zap of a static
TCC and shift solenoids in the transmission. For more discharge.
information on the TCC and shift solenoids, refer to
4L30-E Automatic Transmission section.
TS23793
There are several ways for a person to become statically

charged. The most common methods of charging are by
0008
friction and induction.
Use of Circuit Testing Tools D An example of charging by friction is a person sliding
Do not use a test light to diagnose the powertrain across a vehicle seat.
electrical systems unless specifically instructed by the D Charge by induction occurs when a person with well
diagnostic procedures. Use Connector Test Adapter Kit J insulated shoes stands near a highly charged object
35616 whenever diagnostic procedures call for probing and momentary touches ground. Charges of the
connectors. same polarity are drained off leaving the person
highly charged with the opposite polarity. Static
Aftermarket Electrical and Vacuum charges can cause damage, therefore it is important
to use care when handling and testing electronic
Equipment components.
Aftermarket (add-on) electrical and vacuum equipment is
defined as any equipment which connects to the vehicle’s NOTE: To prevent possible electrostatic discharge
electrical or vacuum systems that is installed on a vehicle damage, follow these guidelines:
after it leaves the factory. No allowances have been D Do not touch the PCM connector pins or soldered
made in the vehicle design for this type of equipment. components on the PCM circuit board.
NOTE: No add-on vacuum equipment should be added D Do not open the replacement part package until the
to this vehicle. part is ready to be installed.
D Before removing the part from the package, ground
NOTE: Add-on electrical equipment must only be the package to a known good ground on the vehicle.
connected to the vehicle’s electrical system at the battery
(power and ground). D If the part has been handled while sliding across the
seat, while sitting down from a standing position, or
Add-on electrical equipment, even when installed to while walking a distance, touch a known good ground
these guidelines, may still cause the powertrain system to before installing the part.
malfunction. This may also include equipment not
connected to the vehicle electrical system such as Upshift Lamp
portable telephones and radios. Therefore, the first step
Refer to Manual Transmission section.
in diagnosing any powertrain problem is to eliminate all
aftermarket electrical equipment from the vehicle. After
this is done, if the problem still exists, it may be diagnosed General Description (Air Induction)
in the normal manner.
Air Induction System
Electrostatic Discharge Damage The air induction system filters contaminants from the
Electronic components used in the PCM are often outside air, and directs the progress of the air as it is
designed to carry very low voltage. Electronic drawn into the engine. A remote-mounted air cleaner
prevents dirt and debris in the air from entering the less than 80%, the PCM again begins to pulse the
engine. The air duct assembly routes filtered air to the injectors “ON” and “OFF,” allowing fuel into the cylinders.
throttle body. Air enters the engine by to following steps:
1. Through the throttle body. Deceleration Mode
2. Into the common chamber. The PCM reduces the amount of fuel injected when it
detects a decrease in the throttle position and the air flow.
3. Through the cylinder head intake ports.
When deceleration is very fast, the PCM may cut off fuel
4. Into the cylinders. completely for short periods.
Engine Speed/Vehicle Speed/Fuel Disable

Mode
The PCM monitors engine speed. It turns off the fuel
injectors when the engine speed increase above 6400
RPM. The fuel injectors are turned back on when engine
speed decreases below 6150 RPM.
Fuel Cutoff Mode

No fuel is delivered by the fuel injectors when the ignition
is “OFF.” This prevents engine run-on. In addition, the
PCM suspends fuel delivery if no reference pulses are
detected (engine not running) to prevent engine flooding.
Fuel Injector
The sequential multiport fuel injection (SFI) fuel injector is
a solenoid-operated device controlled by the PCM. The
PCM energizes the solenoid, which opens a valve to allow
055RV010
fuel delivery.
The fuel is injected under pressure in a conical spray
pattern at the opening of the intake valve. Excess fuel not
General Description (Fuel Metering) used by the injectors passes through the fuel pressure
regulator before being returned to the fuel tank.
Acceleration Mode A fuel injector which is stuck partly open will cause a loss
The PCM provides extra fuel when it detects a rapid of fuel pressure after engine shut down, causing long
increase in the throttle position and the air flow. crank times.
Battery Voltage Correction Mode
When battery voltage is low, the PCM will compensate for
the weak spark by increasing the following:
D The amount of fuel delivered.
D The idle RPM.
D Ignition dwell time.
CMP Signal
The PCM uses this signal to determine the position of the
number 1 piston during its power stroke, allowing the
PCM to calculate true sequential multiport fuel injection
(SFI). Loss of this signal will set a DTC P0341. If the CMP
signal is lost while the engine is running, the fuel injection
system will shift to a calculated sequential fuel injection
based on the last fuel injection pulse, and the engine will
continue to run. The engine can be restarted and will run
in the calculated sequential mode as long as the fault is
present, with a 1-in-6 chance of being correct. 014RY00009
Clear Flood Mode Fuel Metering System Components

Clear a flooded engine by pushing the accelerator pedal The fuel metering system is made up of the following
down all the way. The PCM then de-energizes the fuel parts:
injectors. The PCM holds the fuel injectors de-energized D The fuel injectors.
as long as the throttle remains above 80% and the engine
D The throttle body.
speed is below 800 RPM. If the throttle position becomes
D The fuel rail.
D The fuel pressure regulator.
D The PCM.
D The crankshaft position (CKP) sensor.
D The camshaft position (CMP) sensor.
D The ION sensing module.
D The fuel pump.
D The fuel pump relay.
Basic System Operation
The fuel metering system starts with the fuel in the fuel
tank. An electric fuel pump, located in the fuel tank,
pumps fuel to the fuel rail through an in-line fuel filter. The
pump is designed to provide fuel at a pressure above the
pressure needed by the injectors. A fuel pressure
regulator in the fuel rail keeps fuel available to the fuel
injectors at a constant pressure. A return line delivers
unused fuel back to the fuel tank. Refer to Section 6C for
further information on the fuel tank, line filter, and fuel
pipes. 014RY00010
Fuel Metering System Purpose Fuel Pump Electrical Circuit

The basic function of the air/fuel metering system is to When the key is first turned “ON,” the PCM energizes the
control the air/fuel delivery to the engine. Fuel is delivered fuel pump relay for two seconds to build up the fuel
to the engine by individual fuel injectors mounted in the pressure quickly. If the engine is not started within two
intake manifold near each intake valve. seconds, the PCM shuts the fuel pump off and waits until
The main control sensor is the heated oxygen sensor the engine is cranked. When the engine is cranked and
(HO2S) located in the exhaust system. The HO2S tells the 58 X crankshaft position signal has been detected by
the PCM how much oxygen is in the exhaust gas. The the PCM, the PCM supplies 12 volts to the fuel pump relay
PCM changes the air/fuel ratio to the engine by controlling to energize the electric in-tank fuel pump.
the amount of time that fuel injector is “ON.” The best An inoperative fuel pump will cause a “no-start” condition.
mixture to minimize exhaust emissions is 14.7 parts of air A fuel pump which does not provide enough pressure will
to 1 part of gasoline by weight, which allows the catalytic result in poor performance.
converter to operate most efficiently. Because of the
constant measuring and adjusting of the air/fuel ratio, the Fuel Rail
fuel injection system is called a “closed loop” system. The fuel rail is mounted to the top of the engine and
The PCM monitors signals from several sensors in order distributes fuel to the individual injectors. Fuel is
to determine the fuel needs of the engine. Fuel is delivered to the fuel inlet tube of the fuel rail by the fuel
delivered under one of several conditions called “modes.” lines. The fuel goes through the fuel rail to the fuel
All modes are controlled by the PCM. pressure regulator. The fuel pressure regulator maintains
a constant fuel pressure at the injectors. Remaining fuel
Fuel Pressure Regulator is then returned to the fuel tank.
The fuel pressure regulator is a diaphragm-operated
relief valve mounted on the fuel rail with fuel pump
pressure on one side and manifold pressure on the other
side. The fuel pressure regulator maintains the fuel
pressure available to the injector at three times
barometric pressure adjusted for engine load. It may be
serviced separate.
If the pressure is too low, poor performance and a DTC
P0131, DTC P0151,DTC P0171 or DTC P1171 will be the
result. If the pressure is too high, excessive odor and/or a
DTC P0132, DTC P0152,DTC P0172 will be the result.
Refer to Fuel System Diagnosis for information on
diagnosing fuel pressure conditions.
055RV009
Run Mode
The run mode has the following two conditions:
D Open loop
D Closed loop
When the engine is first started the system is in “open
loop” operation. In “open loop,” the PCM ignores the
signal from the heated oxygen sensor (HO2S). It
calculates the air/fuel ratio based on inputs from the TP,
ECT, and MAF sensors.
The system remains in “open loop” until the following
conditions are met:
D The HO2S has a varying voltage output showing that
it is hot enough to operate properly (this depends on
temperature).
D The ECT has reached a specified temperature.
D A specific amount of time has elapsed since starting
the engine.
D Engine speed has been greater than a specified RPM 025RY00005
since start-up.
The specific values for the above conditions vary with
different engines and are stored in the programmable General Description (Electronic
read only memory (PROM). When these conditions are Ignition System)
met, the system enters “closed loop” operation. In
“closed loop,” the PCM calculates the air/fuel ratio Camshaft Position (CMP) Sensor
(injector on-time) based on the signal from the HO2S. CMP is located Left Rear cylinder head. When the
This allows the air/fuel ratio to stay very close to 14.7:1. Hall-effect switch is activated, it grounds the signal line to
the PCM, pulling the camshaft position sensor signal
Starting Mode circuit’s applied voltage low. This is a CMP signal. The
When the ignition is first turned “ON,” the PCM energizes CMP signals is created as piston #1 is approximately 25°
the fuel pump relay for two seconds to allow the fuel pump after top dead counter on the power stroke. If the correct
to build up pressure. The PCM then checks the engine CMP signal is not received by the PCM, DTC P0341 will
coolant temperature (ECT) sensor and the throttle be set.
position (TP) sensor to determine the proper air/fuel ratio
for starting.
The PCM controls the amount of fuel delivered in the
starting mode by adjusting how long the fuel injectors are
energized by pulsing the injectors for very short times.
Throttle Body Unit

The throttle body has a throttle plate to control the amount
of air delivered to the engine. The TP sensor are also
mounted on the throttle body. Vacuum ports located
behind the throttle plate provide the vacuum signals
needed by various components.
Engine coolant is directed through a coolant cavity in the
throttle body to warm the throttle valve and to prevent
icing.
0014
Crankshaft Position (CKP) Sensor

The crankshaft position (CKP) sensor provides a signal
used by the powertrain control module (PCM) to calculate
the ignition sequence. The sensor initiates the 58X
reference pulses which the PCM uses to calculate RPM
and crankshaft position. Refer to Electronic Ignition
System section for additional information.
Electronic Ignition
The electronic ignition system controls fuel combustion
by providing a spark to ignite the compressed air/fuel
mixture at the correct time. To provide optimum engine
performance, fuel economy, and control of exhaust
emissions, the PCM controls the spark advance of the
ignition system. Electronic ignition has the following
advantages over a mechanical distributor system:
D No moving parts.
D Less maintenance.
D Remote mounting capability.
D No mechanical load on the engine.
D More coil cooldown time between firing events.
D Elimination of mechanical timing adjustments.
D Increased available ignition coil saturation time.
060RY00022
Ignition Control
The ignition control (IC) spark timing is the PCM’s method
of controlling the spark advance and the ignition dwell.
The IC spark advance and the ignition dwell are
calculated by the PCM using the following inputs:
D Engine speed.
D Crankshaft position (58X reference).
D Camshaft position (CMP) sensor.
D Engine coolant temperature (ECT) sensor.
D ION sensing module.
D Park/Neutral position (PRNDL input).
D Vehicle speed (vehicle speed sensor).
0013
D PCM and ignition system supply voltage.
D The crankshaft positron (CKP) sensor sends the
Ignition Coils PCM a 58X signal related to the exact position of the
A separate coil-at-plug module is located at each spark crankshaft.
plug. The coil-at-plug module is attached to the engine
with two screws. It is installed directly to the spark plug by
an electrical contact inside a rubber boot. A three-way
connector provides 12-volt primary supply from the
15-amp ignition fuse, a ground-switching trigger line from
the PCM, and a ground.
TS22909 060RY00029
D The camshaft position (CMP) sensor sends a signal

related to the position of the camshaft. Ignition Control PCM Output
Based on these sensor signals and engine load The PCM provides a zero volt (actually about 100 mV to
information, the PCM sends 5V to each ignition coil. 200 mV) or a 5-volt output signal to the ignition control (IC)
module. Each spark plug has its own primary and
secondary ignition coil assembly (”coil-at-plug”) located
at the spark plug itself. When the ignition coil receives the
5-volt signal from the PCM, it provides a ground path for
the B+ supply to the primary side of the coil-at -plug
module. When the PCM shuts off the 5-volt signal to the
ION sensing module, the ground path for the primary coil
is broken. The magnetic field collapses and induces a
high voltage secondary impulse which fires the spark plug
and ignites the air/fuel mixture.
The circuit between the PCM and the ignition coil is
monitored for open circuits, shorts to voltage, and shorts
to ground. If the PCM detects one of these events, it will
set one of the following DTCs:
D P0351: Ignition coil Fault on Cylinder #1
060RY00116 D P0355: Ignition coil Fault on Cylinder #5
This module has the function to energize and de-energize D P0356: Ignition coil Fault on Cylinder #6
the primary ignition coil in response to signals from the
PCM. The Throttle PCM controls ignition timing and dwell Powertrain Control Module (PCM)
time.
The PCM is responsible for maintaining proper spark and
Continuity and out-or-range value check:
fuel injection timing for all driving conditions. To provide
optimum driveability and emissions, the PCM monitors
the Electronic Spark Timing (EST) line by monitoring EST
the input signals from the following components in order
signals. A failure determination is made when the signal
to calculate spark timing:
voltage remains higher or lower than the threshold for
corresponding fault code beyond a predetermined time D Engine coolant temperature (ECT) sensor.
period. D Intake air temperature (IAT) sensor.
Diagnosis enabling conditions are as follows: D Mass air flow (MAF) sensor.
D RPM is higher than the specified threshold. D PRNDL input from transmission range switch.
D EST line is enabled. D Throttle position (TP) sensor.
D Vehicle speed sensor (VSS) .
D Crankshaft position (CKP) sensor.
Spark Plug
Although worn or dirty spark plugs may give satisfactory
operation at idling speed, they frequency fail at higher
engine speeds. Faulty spark plugs may cause poor fuel
economy, power loss, loss of speed, hard starting and
generally poor engine performance. Follow the
scheduled maintenance service recommendations to
ensure satisfactory spark plug performance. Refer to
Maintenance and Lubrication section.
Normal spark plug operation will result in brown to
grayish-tan deposits appearing on the insulator portion of
the spark plug. A small amount of red-brown, yellow, and
white powdery material may also be present on the
insulator tip around the center electrode. These deposits
are normal combustion by-products of fuels and
lubricating oils with additives. Some electrode wear will
also occur. Engines which are not running properly are
often referred to as “misfiring.” This means the ignition
spark is not igniting the air/fuel mixture at the proper time. TS23995
While other ignition and fuel system causes must also be Excessive gap means that the air space between the
considered, possible causes include ignition system center and the side electrodes at the bottom of the spark
conditions which allow the spark voltage to reach ground plug is too wide for consistent firing. This may be due to
in some other manner than by jumping across the air gap improper gap adjustment or to excessive wear of the
at the tip of the spark plug, leaving the air/fuel mixture electrode during use. A check of the gap size and
unburned. Refer to DTC P0300. Misfiring may also occur comparison to the gap specified for the vehicle in
when the tip of the spark plug becomes overheated and Maintenance and Lubrication section will tell if the gap is
ignites the mixture before the spark jumps. This is too wide. A spark plug gap that is too small may cause an
referred to as “pre-ignition.” unstable idle condition. Excessive gap wear can be an
Spark plugs may also misfire due to fouling, excessive indication of continuous operation at high speeds or with
gap, or a cracked or broken insulator. If misfiring occurs engine loads, causing the spark to run too hot. Another
before the recommended replacement interval, locate possible cause is an excessively lean fuel mixture.
and correct the cause.
Carbon fouling of the spark plug is indicated by dry, black
carbon (soot) deposits on the portion of the spark plug in
the cylinder. Excessive idling and slow speeds under
light engine loads can keep the spark plug temperatures
so low that these deposits are not burned off. Very rich
fuel mixtures or poor ignition system output may also be
the cause. Refer to DTC P0172.
Oil fouling of the spark plug is indicated by wet oily
deposits on the portion of the spark plug in the cylinder,
usually with little electrode wear. This may be caused by
oil during break-in of new or newly overhauled engines.
Deposit fouling of the spark plug occurs when the normal
red-brown, yellow or white deposits of combustion by
products become sufficient to cause misfiring. In some
cases, these deposits may melt and form a shiny glaze on
the insulator around the center electrode. If the fouling is
found in only one or two cylinders, valve stem clearances
or intake valve seals may be allowing excess lubricating
oil to enter the cylinder, particularly if the deposits are TS23992
heavier on the side of the spark plug facing the intake Low or high spark plug installation torque or improper
valve. seating can result in the spark plug running too hot and
can cause excessive center electrode wear. The plug
and the cylinder head seats must be in good contact for
proper heat transfer and spark plug cooling. Dirty or
damaged threads in the head or on the spark plug can
keep it from seating even though the proper torque is
applied. Once spark plugs are properly seated, tighten
them to the torque shown in the Specifications Table. Low
torque may result in poor contact of the seats due to a
loose spark plug. Overtightening may cause the spark
plug shell to be stretched and will result in poor contact D ”Heat shock” breakage in the lower insulator tip
between the seats. In extreme cases, exhaust blow-by generally occurs during several engine operating
and damage beyond simple gap wear may occur. conditions (high speeds or heavy loading) and may be
Cracked or broken insulators may be the result of caused by over-advanced timing or low grade fuels.
improper installation, damage during spark plug Heat shock refers to a rapid increase in the tip
re-gapping, or heat shock to the insulator material. Upper temperature that causes the insulator material to
insulators can be broken when a poorly fitting tool is used crack.
during installation or removal, when the spark plug is hit Spark plugs with less than the recommended amount of
from the outside, or is dropped on a hard surface. Cracks service can sometimes be cleaned and re-gapped , then
in the upper insulator may be inside the shell and not returned to service. However, if there is any doubt about
visible. Also, the breakage may not cause problems until the serviceability of a spark plug, replace it. Spark plugs
oil or moisture penetrates the crack later. with cracked or broken insulators should always be
replaced.
A/C Clutch Diagnosis
A/C Clutch Circuit Operation
A 12-volt signal is supplied to the A/C request input of the
PCM when the A/C is selected through the A/C control
switch.
The A/C compressor clutch relay is controlled through the
PCM. This allows the PCM to modify the idle air control
position prior to the A/C clutch engagement for better idle
quality. If the engine operating conditions are within their
specified calibrated acceptable ranges, the PCM will
enable the A/C compressor relay. This is done by
providing a ground path for the A/C relay coil within the
PCM. When the A/C compressor relay is enabled,
battery voltage is supplied to the compressor clutch coil.
The PCM will enable the A/C compressor clutch
whenever the engine is running and the A/C has been
requested. The PCM will not enable the A/C compressor
TS23994
clutch if any of the following conditions are met:
A broken or cracked lower insulator tip (around the center
electrode) may result from damage during re-gapping or D The throttle is greater than 90%.
from “heat shock” (spark plug suddenly operating too D The engine speed is greater than 6315 RPM.
hot). D The ECT is greater than 119°C (246°F).
D The IAT is less than 5°C (41°F).
D The throttle is more than 80% open.
A/C Clutch Circuit Purpose

The A/C compressor operation is controlled by the
powertrain control module (PCM) for the following
reasons:
D It improvises idle quality during compressor clutch
engagement.
D It improvises wide open throttle (WOT) performance.
D It provides A/C compressor protection from operation
with incorrect refrigerant pressures.
The A/C electrical system consists of the following
components:
D The A/C control head.
D The A/C refrigerant pressure switches.
D The A/C compressor clutch.
TS23993 D The A/C compressor clutch relay.
D Damage during re-gapping can happen if the gapping D The PCM.
tool is pushed against the center electrode or the
insulator around it, causing the insulator to crack. A/C Request Signal
When re-gapping a spark plug, make the adjustment
by bending only the ground side terminal, keeping the This signal tells the PCM when the A/C mode is selected
tool clear of other parts. at the A/C control head. The PCM uses this to adjust the
idle speed before turning on the A/C clutch. The A/C
compressor will be inoperative if this signal is not Poor idle, stalling and poor driveability can be caused by:
available to the PCM. D A malfunctioning purge solenoid.
Refer to A/C Clutch Circuit Diagnosis section for A/C D A damaged canister.
wiring diagrams and diagnosis for A/C electrical system.
D Hoses that are split, cracked, or not connected
properly.
General Description (Evaporative
(EVAP) Emission System) Enhanced Evaporative Emission Control
System
EVAP Emission Control System Purpose The basic purpose of the Enhanced Evaporative
The basic evaporative emission (EVAP) control system Emissions control system is the same as other EVAP
used on all vehicles is the charcoal canister storage systems. A charcoal-filled canister captures and stores
method. Gasoline vapors from the fuel tank flow into the gasoline fumes. When the PCM determines that the time
canister through the inlet labeled “TANK.” These vapors is right, it opens a purge valve which allows engine
are absorbed into the activated carbon (charcoal) storage vacuum to draw the fumes into the intake manifold.
device (canister) in order to hold the vapors when the The difference between this and other systems is that the
vehicle is not operating. The canister is purged by PCM PCM monitors the vacuum and/or pressure in the system
control when the engine coolant temperature is over 60°C to determine if there is any leakage. If the PCM
(140°F), the IAT reading is over 10°C (50°F), and the determines that the EVAP system is leaking or not
engine has been running. Air is drawn into the canister functioning properly, it sets a Diagnostic Trouble Code
through the air inlet grid. The air mixes with the vapor and (DTC) in the PCM memory.
the mixture is drawn into the intake manifold. The enhanced EVAP system is required to detect
evaporative fuel system leaks as small as 0.040 in. (1.0
EVAP Emission Control System Operation mm) between the fuel filler cap and purge solenoid. The
The EVAP canister purge is controlled by a solenoid valve system can test the evaporative system integrity by
that allows the manifold vacuum to purge the canister. applying a vacuum signal (ported or manifold) to the fuel
The powertrain control module (PCM) supplies a ground tank to create a small vacuum. The PCM then monitors
to energize the solenoid valve (purge on). The EVAP the ability of the system to maintain the vacuum. If the
purge solenoid control is pulse-width modulated (PWM) vacuum remains for a specified period of time, there are
(turned on and off several times a second). The duty no evaporative leaks and a PASS report is sent to the
cycle (pulse width) is determined by engine operating diagnostic executive. If there is a leak, the system either
conditions including load, throttle positron, coolant will not achieve a vacuum, or a vacuum cannot be
temperature and ambient temperature. The duty cycle is maintained. Usually, a failure can only be detected after a
calculated by the PCM. The output is commanded when cold start with a trip of sufficient length and driving
the appropriate conditions have been met. These conditions to run the needed tests. The enhanced EVAP
conditions are: system diagnostic will conduct up to eight specific
D The engine is fully warmed up. sub-tests to detect fault conditions. If the diagnostic fails
D The engine has been running for a specified time. a sub-test, the PCM will store a Diagnostic Trouble Code
(DTC) to indicate the type of detected.
D The IAT reading is above 10°C (50°F).
A continuous purge condition with no purge commanded
by the PCM will set a DTC P1441.
TS30006
Legend (11) Vent Solenoid Driver Signal from PCM

(1) Vent Solenoid (12) Vent Filter
(2) EVAP Purge Solenoid (13) Fuel Tank Pressure Sensor
(3) Throttle Body (14) Fuel Tank Pressure Signal to PCM
(4) Fuel Filler Neck (15) 5 Volt Reference “A” Circuit from PCM
(5) Fuel Tank (16) Sensor Ground Circuit from PCM
(6) Rollover Valve (17) Fuel Level Sensor
(7) EVAP Canister (18) Fuel Level Signal to PCM
(8) Ignition Feed (19) 5 Volt Return
(10) EVAP Purge Solenoid Driver Signal from PCM
Electrical Components voltage and a ground to the sensor. The sensor will
The electrical components that make up the enhanced return a voltage between 0.1 and 4.9 volts. When the
EVAP system are: air pressure in the fuel tank is equal to the outside air
pressure, such as when the fuel cap is removed, the
D Fuel Tank Pressure Sensor. The fuel tank pressure
output voltage of the sensor will be 1.3 to 1.7 volts.
sensor is a three-wire strain gauge sensor similar to a
common MAP sensor. However, the fuel tank When the air pressure in the fuel tank is 4.5 in. H2O
pressure sensor has very different electrical (1.25 kPa), the sensor output voltage will be 0.5 ± 0.2 V.
characteristics due to its pressure differential design. When there is neither vacuum nor pressure in the fuel
The sensor measures the difference between the air tank, the sensor voltage will be 1.5 V. At –14 in. H2O
pressure (or vacuum) in the fuel tank and the outside (–3.75 kPa), the sensor voltage will be 4.5 ± 0.2 V.
air pressure.
The sensor mounts at the top of the fuel pump
assembly. A three-wire electrical harness connects it to
the PCM. The PCM supplies a five-volt reference
D EVAP Canister Purge Solenoid. Normally closed, the D Fuel Level Sensor. The fuel level sensor is an
purge solenoid opens upon the PCM’s signal to allow important input to the PCM for the enhanced EVAP
engine vacuum to purge gasoline fumes from the system diagnostic. The PCM needs fuel level
canister. Mounted on the water pipe to front of the information to know the volume of fuel in the tank.
engine assembly. The fuel level affects the rate of change of air
pressure in the EVAP system. Several of the
enhanced EVAP system diagnostic sub-tests are
dependent upon correct fuel level information. The
diagnostic will not run when the tank is less than 15%
or more than 85% full. Be sure to diagnose any Fuel
Level Sensor DTCs first, as they can cause other
DTCs to set.
014RW093
D EVAP Canister Vent Solenoid. Located next to the

canister, the vent solenoid opens to allow air into the
EVAP system. Fresh air is necessary to completely
remove gasoline fumes from the canister during
purge. The EVAP vent solenoid closes to seal off the
evaporative emissions system for leak testing.
TS23796
D Manifold Absolute Pressure (MAP) Sensor. The

PCM compares the signals from the fuel tank
pressure sensor and the MAP sensor to ensure that a
relative vacuum is maintained the EVAP system.
014RW148
055RW004
Non-Electrical Components D Disconnected or damaged EVAP vent hose
D Purge/Vacuum Hoses. Made of rubber compounds, D Disconnected, damaged, pinched, or blocked fuel
these hoses route the gasoline fumes from their tank vapor line
sources to the canister and from the canister to the D Disconnected or faulty EVAP purge solenoid
intake air flow. D Disconnected or faulty EVAP vent solenoid
D EVAP Canister. Mounted on a bracket ahead of the D Open ignition feed circuit to the EVAP vent or purge
fuel tank, the canister stores fuel vapors until the PCM solenoid
determines that engine conditions are right for them
to be remove and burned. D Damaged EVAP canister
D Fuel Tank. The tank has a built-in air space designed D Leaking fuel sender assembly O-ring
for the collection of gasoline fumes. D Leaking fuel tank or fuel filler neck
A restricted or blocked EVAP vent path is detected by
drawing vacuum into the EVAP system, turning “OFF” the
EVAP vent solenoid and the EVAP purge solenoid (EVAP
vent solenoid “OPEN,” EVAP purge Pulse Width
Modulate (PWM) “0%”) and monitoring the fuel tank
vacuum sensor input. With the EVAP vent solenoid open,
any vacuum in the system should decrease quickly
unless the vent path is blocked. A blockage like this will
set DTC P0446 and can be caused by the following
conditions:
D Faulty EVAP vent solenoid (stuck closed)
D Plugged, kinked or pinched vent hose
D Shorted EVAP vent solenoid driver circuit
D Plugged EVAP canister
The PCM supplies a ground to energize the purge
solenoid (purge “ON”). The EVAP purge control is PWM,
or turned “ON” and “OFF,” several times a second. The
duty cycle (pulse width) is determined by engine
014RW145
operating conditions including load, throttle position,
D Vacuum Source. The vacuum source is split between coolant temperature and ambient temperature. The duty
two ports, one on either side of the throttle body. cycle is calculated by the PCM and the output is
D Fuel Cap. The fuel cap is designed to be an integral commanded when the appropriate conditions have been
part of the EVAP system. met.
The system checks for conditions that cause the EVAP
System Fault Detection system to purge continuously by commanding the EVAP
The EVAP leak detection strategy is based on applying vent solenoid “ON” and the EVAP purge solenoid “OFF”
vacuum to the EVAP system and monitoring vacuum (EVAP vent solenoid “CLOSED,” EVAP purge PWM
decay. The PCM monitors vacuum level via the fuel tank “0%”). If fuel tank vacuum level increases during the test,
pressure sensor. At an appropriate time, the EVAP purge a continuous purge flow condition is indicated, which will
solenoid and the EVAP vent solenoid are turned “ON,” set a DTC P1441. This can be cause by the following
allowing the engine vacuum to draw a small vacuum on conditions:
the entire evaporative emission system. D EVAP purge solenoid leaking
After the desired vacuum level has been achieved, the
D EVAP purge and engine vacuum lines switched at the
EVAP purge solenoid is turned “OFF,” sealing the system. EVAP purge solenoid
A leak is detected by monitoring for a decrease in vacuum
level over a given time period, all other variables D EVAP purge solenoid driver circuit grounded
remaining constant. A small leak in the system will cause
DTC P0442 to be set. General Description (Exhaust Gas
If the desired vacuum level cannot be achieved in the test
described above, a large leak or a faulty EVAP purge Recirculation (EGR) System)
solenoid is indicated.
EGR Purpose
Leaks can be caused by the following conditions:
D Disconnected or faulty fuel tank pressure sensor The exhaust gas recirculation (EGR) system is use to
reduce emission levels of oxides of nitrogen (NOx). NOx
D Missing or faulty fuel cap emission levels are caused by a high combustion
D Disconnected, damaged, pinched, or blocked EVAP temperature. The EGR system lowers the NOx emission
purge line levels by decreasing the combustion temperature.
D Rough idle.
D DTC P0300 (misfire detected).
Too little or no EGR flow may allow combustion
temperatures to get too high. This could cause:
D Spark knock (detonation).
D Engine overheating.
D Emission test failure.
D DTC P0401 (EGR flow test).
D Poor fuel economy.
057RW002
Linear EGR Valve

The main element of the system is the linear EGR valve.
The EGR valve feeds small amounts of exhaust gas back
into the combustion chamber. The fuel/air mixture will be
diluted and combustion temperatures reduced.
Linear EGR Control

The PCM monitors the EGR actual positron and adjusts
the pintle position accordingly. The uses information from
0017
the following sensors to control the pintle position:
D Engine coolant temperature (ECT) sensor. EGR Pintle Position Sensor
D Throttle position (TP) sensor. The PCM monitors the EGR valve pintle position input to
D Mass air flow (MAF) sensor. endure that the valve responds properly to commands
from the PCM and to detect a fault if the pintle position
Linear EGR Valve Operation and Results sensor and control circuits are open or shorted. If the
of Incorrect Operation PCM detects a pintle position signal voltage outside the
The linear EGR valve is designed to accurately supply normal range of the pintle position sensor, or a signal
EGR to the engine independent of intake manifold voltage that is not within a tolerance considered
vacuum. The valve controls EGR flow from the exhaust acceptable for proper EGR system operation, the PCM
to the intake manifold through an orifice with a PCM will set DTC P1406.
controlled pintle. During operation, the PCM controls
pintle position by monitoring the pintle position feedback General Description (Positive
signal. The feedback signal can be monitored with a Tech
2 as “Actual EGR Pos.” “Actual EGR Pos.” should always
Crankcase Ventilation (PCV) System)
be near the commanded EGR position (”Desired EGR Crankcase Ventilation System Purpose
Pos.”). If a problem with the EGR system will not allow the
PCM to control the pintle position properly, DTC P1406 The crankcase ventilation system is use to consume
will set. The PCM also tests for EGR flow. If incorrect flow crankcase vapors in the combustion process instead of
is detected, DTC P0401 will set. If DTCs P0401 and/or venting them to the atmosphere. Fresh air from the
P1406 are set, refer to the DTC charts. throttle body is supplied to the crankcase and mixed with
The linear EGR valve is usually activated under the blow-by gases. This mixture is then passed through the
following conditions: positive crankcase ventilation (PCV) valve into the
common chamber.
D Warm engine operation.
D Above-idle speed. Crankcase Ventilation System Operation
Too much EGR flow at idle, cruise or cold operation may The primary control is through the positive crankcase
cause any of the following conditions to occur: ventilation (PCV) valve. The PCV valve meters the flow at
D Engine stalls after a cold start. a rate that depends on the intake vacuum. The PCV valve
D Engine stalls at idle after deceleration. restricts the flow when the inlet vacuum is highest. In
D Vehicle surges during cruise.
addition, the PCV valve can seal the common chamber A plugged valve or PCV hose may cause the following
off in case of sudden high pressure in the crankcase. conditions:
D Rough idle.
D Stalling of slow idle speed.
D Oil leaks.
D Sludge in the engine.
A leaking PCV hose would cause:
D Rough idle.
D Stalling.
D High idle speed.
028RV002
While the engine is running, exhaust fuses and small

amounts of the fuel/air mixture escape past the piston
rings and enter the crankcase. These gases are mixed
with clean air entering through a tube from the air intake
duct.
028RW002
During normal, part-throttle operation, the system is

designed to allow crankcase gases to flow through the
PCV valve into the throttle body to be consumed by
normal combustion.
Special Tools
TOOL NO. TOOL NO.
TOOL NAME TOOL NAME
J 39200
J 23738-A
High Impedance
Vacuum Pump with
Multimeter (Digital
Gauge
Voltmeter – DVM)
(1) PCMCIA Card

(2) RS232 Loop Back
BT-8515/8515V
Connector
Exhaust Back Pressure
(3) SAE 16/19 Adapter
Tester
(4) DLC Cable
(5) TECH–2
J 39194-B
J 34142-B
Heated Oxygen Sensor
Unpowered Test Light
Wrench
Connector Test Adapter J 35689-A

Kit J 35616-A/BT-8637 Terminal Remover
J 28742-A
J 26792/BT-7220-1
Weather Pack II
Spark Tester
Terminal Remover
J 34730-E
Port Fuel Injection J 39021-90
Diagnostic Kit Injector Switch Box
TOOL NO.
ILLUSTRATION
TOOL NAME
J 39021-65
Injector Test Light
J 414162
Ultrasonic Leak Detector
1. J 41416 Ultrasonic Leak Detector is a

microprocessor-based device used to detect leaks in
the enhanced evaporative emission control system.
The evaporative system is pressurized to 30 inches of
water using the J 41413 EVAP Pressure/Purge
Diagnostic System. Small leaks in the EVAP system
will emit sound at a high frequency undetectable by a
human ear but detectable with the J 41416. The
technician traces along the evaporative system and
can pinpoint leaks due to corroded lines, cracked
hoses, or a damaged EVAP component. The
detector includes a high quality set of headphones to
block out surrounding shop noise and the LED
sensitivity meter allows a visual reference for locating
leaks in conjunction with the audio output heard
through the headphones. Powered by (1) nine volt
battery.
ENGINE EXHAUST 6F–1
TROOPER
ENGINE
ENGINE EXHAUST
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . 6F–2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F–5
Front Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . 6F–3 Exhaust Silencer . . . . . . . . . . . . . . . . . . . . . . . . 6F–6
Front Exhaust Pipe and Associated Parts . 6F–3 Exhaust Silencer and Associated Parts . . . 6F–6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F–3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F–6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F–3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F–6
Three Way Catalytic Converter LH . . . . . . . . . 6F–4 Rear Exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . 6F–7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F–4 Rear Exhaust pipe and Associated Parts . 6F–7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F–4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F–7
Three Way Catalytic Converter RH . . . . . . . . 6F–5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F–7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F–5 Main Data and Specifications . . . . . . . . . . . . . 6F–8
6F–2 ENGINE EXHAUST
General Description
150RY00002
When inspecting or replacing exhaust system Three Way Catalytic Converter

components, make sure there is adequate clearance The three way catalytic converter is an emission control
from all points on the underbody to prevent overheating
device added to the exhaust system to reduce pollutants
the floor pan and possible damage to the passenger
from the exhaust gas stream.
compartment insulation and trim materials.
CAUTION: The catalytic converter requires the use
Check complete exhaust system and nearby body areas of unleaded fuel only.
and rear compartment lid for broken, damaged, missing
or mispositioned parts, open seams, holes, loose Periodic maintenance of the exhaust system is not
connections or other deterioration which could permit required. If the vehicle is raised for other service, it is
exhaust fumes to seep into the rear compartment or advisable to check the condition of the complete exhaust
passenger compartment. Dust or water in the rear system.
compartment may be an indication of a problem in one of A dual bed monolith catalytic converter is used in
these areas. Any faulty areas should be corrected combination with three way catalytic converter.
immediately. Catalytic Types:
Three way (Reduction/Oxidation) catalyst
Hangers The catalyst coating on the three way (reduction)
Various types of hangers are used to support exhaust converter contains platinum and rhodium which lowers
system(s). These include conventional rubber straps, the levels of nitrous oxide (NOx) as well as hydrocarbons
rubber rings, and rubber blocks. (HC) and carbon monoxide (Co).
The installation of exhaust system supports is very Gasket
important, as improperly installed supports can cause
annoying vibrations which can be difficult to diagnose. The gasket must be replaced whenever a new exhaust
pipe, muffler or catalytic converter is installed.
Front Exhaust Pipe

Front Exhaust Pipe and Associated Parts
150RY001
Legend (6) Front Exhaust Pipe LH

(1) Front Exhaust Pipe RH Fixing Nuts (7) O2 Sensor Terminal Connector
(2) O2 Sensor Terminal Connector (8) Front Exhaust Pipe LH Fixing Nuts
(3) Front Exhaust Pipe RH Fixing Bolts and Nuts (9) O2 Sensor Terminal Connector
(4) Front Exhaust Pipe Fixing Bolts and Nuts (10) Front Exhaust Pipe RH
(5) O2 Sensor Terminal Connector
1. Disconnect battery ground cable. 1. Install front exhaust pipe (10)(6) and tighten three
2. Raise the vehicle and support with suitable safety stud nuts (1)(8) and two nuts (3)(4) to the specified
stands. torque.
3. Disconnect O2 sensor harness connector Torque
(2)(5)(7)(9). Stud Nuts : 67 N·m (49 lb ft)
4. Remove front exhaust pipe fixing nuts (3)(4). Nuts : 43 N·m (32 lb ft)
5. Remove front exhaust pipe fixing three stud nuts from 2. Reconnect O2 sensor harness connector (2)(5)(7)(9).
exhaust manifold (1)(8).
6. Remove front exhaust pipe (6)(10).
Three Way Catalytic Converter LH

1. Disconnect battery ground cable. 1. Install exhaust front pipe (6) and tighten three studs
2. Raise the vehicle and support with suitable safety nuts (1) and two nuts (4)(5) to the specified torque.
stands. Torque
3. Disconnect front O2 sensor harness connector and Stud nuts : 67 N·m (49 lb ft)
rear O2 sensor harness connector (2)(3). Nuts : 43 N·m (32 lb ft)
4. Remove exhaust front pipe fixing three stud nuts (1) 2. Reconnect O2 sensor harness connector (2)(3).
from exhaust manifold side and two nuts (4)(5) from
rear end of exhaust front pipe (6).
150RW013
Legend
(1) Front Exhaust Pipe Fixing Three Stud Nuts
(2) O2 Sensor Harness Connector
(4) Front Exhaust Pipe RH Fixing Bolts and Nuts
(5) Front Exhaust Pipe Fixing Bolts and Nuts
(6) Front Exhaust Pipe LH
Three Way Catalytic Converter RH

1. Disconnect battery ground cable. 1. Install front exhaust pipe (5) and tighten three stud
2. Raise the vehicle and support with suitable safety nuts (1) and two nuts (3) to the specified torque.
stands. Torque
3. Remove torsion bar. Refer to removal procedure in Stud nuts : 67 N·m (49 lb ft)
Front Suspension section. Nuts : 43 N·m (32 lb ft)
4. Disconnect front O2 sensor harness connector (4) 2. Install the torsion bar and readjust the vehicle height.
and rear O2 sensor harness connector (2). Refer to the installation and vehicle height adjustment
5. Remove front exhaust pipe fixing nuts (3). instructions in the Front Suspension Section.
6. Remove three stud nuts (1) from exhaust manifold
then remove the exhaust front pipe (5).
150RW010
Legend
(1) Front Exhaust Pipe Fixing Three Stud Nuts
(3) Front Exhaust Pipe Fixing Bolts and Nuts
(5) Front Exhaust Pipe
Exhaust Silencer
Exhaust Silencer and Associated Parts
E06RW020
Legend (3) Exhaust Silencer Fixing Nuts

(1) Exhaust Silencer (4) Exhaust Silencer Fixing Bolts
(2) Mounting Rubber (5) Exhaust Front Pipe
1. Disconnect battery ground cable. 1. Install the exhaust silencer (1) chassis side and
2. Raise the vehicle and support with suitable safety tighten four nuts to the specified torque.
stands. Nuts: 16 N·m (12 lb ft)
3. Remove exhaust silencer fixing nuts (3) then 2. Install the exhaust silencer and tighten two bolts (4)
disconnect rear exhaust pipe from exhaust silencer. on front exhaust pipe to specified torque.
4. Remove exhaust silencer fixing bolts (4) then Bolts: 43 N·m (32 lb ft)
disconnect exhaust silencer from front exhaust pipe
(5). 3. Install the rear exhaust pipe and tighten on exhaust
silencer to specified torque.
5. Remove exhaust silencer mounting nuts from
chassis side then remove exhaust silencer (1). Nuts: 43 N·m (32 lb ft)
Rear Exhaust pipe

Rear Exhaust pipe and Associated Parts
E06RW021
Legend (2) Rear Exhaust Pipe

(1) Mounting Rubber (3) Rear Exhaust Pipe Fixing Nuts
1. Disconnect battery ground cable. 1. Install the mounting rubber (1).
2. Raise the vehicle and support with suitable safety 2. Install the exhaust pipe (2) and tighten two nuts (3) on
stands. exhaust silencer to specified torque.
3. Remove rear exhaust pipe fixing nuts (3), then Nuts: 43 N·m (32 lb ft)
disconnect rear exhaust pipe from exhaust silencer.
4. Remove mounting rubber (1).
5. Remove rear exhaust pipe (2).

E06RW022
ENGINE LUBRICATION 6G–1
TROOPER
ENGINE
ENGINE LUBRICATION
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 6G–1 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G–10
General Description . . . . . . . . . . . . . . . . . . . . . 6G–2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G–10
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G–3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G–10
Oil Pump and Associated Parts . . . . . . . . . . 6G–3 Oil Pump Oil Seal . . . . . . . . . . . . . . . . . . . . . . . 6G–12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6G–3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G–12
Inspection and Repair . . . . . . . . . . . . . . . . . . 6G–4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G–12
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 6G–5 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G–13
Oil Pan and Crankcase . . . . . . . . . . . . . . . . . . 6G–7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G–13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G–7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G–13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G–7 Main Data and Specification . . . . . . . . . . . . . . 6G–14

systems.
6G–2 ENGINE LUBRICATION
General Description
C06RW002
Legend (10) Crankshaft

(1) Oil Strainer (11) Connecting Rod Bearing
(2) Oil Pump (12) Connecting Rod
(3) Relief Valve (13) Piston
(4) Oil Pressure Switch (14) Oil Gallery; Cylinder Head
(5) Oil Filter (15) Camshaft
(6) Safety Valve (16) Camshaft Journal
(7) Oil Pressure Unit (17) Front Journal; Camshaft Drive Gear
(8) Oil Gallery (18) Rear Journal; Camshaft Drive Gear
(9) Crankshaft Bearing (19) Oil Pan
Oil Pump
Oil Pump and Associated Parts
051RW005
Legend (8) Relief Valve

(1) Crankshaft Timing Pulley (9) Oil Pump Cover
(2) Crankcase with Oil Pan (10) Driven Gear
(3) Oil Pipe (11) Drive Gear
(4) Oil Strainer (12) Oil Seal
(5) Oil Pump Assembly (13) O-ring
(6) Plug (14) Oil Pump Body
(7) Spring
Disassembly 5. Remove oil pump assembly.

6. Remove plug.
1. Remove crankshaft timing pulley.
7. Remove spring.
2. Remove crankcase with oil pan.
8. Remove relief valve.
3. Remove oil pipe.
9. Remove oil pump cover.
4. Remove oil strainer.
10. Remove driven gear.
11. Remove drive gear.
13. Remove O-ring.

CAUTION: Make necessary correction or parts
replacement if wear, damage or any other abnormal
conditions are found during inspection.
Relief Valve (8)
D Check to see that the relief valve slides freely.
D The oil pump must be replaced if the relief valve does
not slide freely.
D Replace the spring and/or the oil pump assembly (5) if
the spring is damaged or badly worn.
051RS004
D Measure the clearance between the drive gear and

driven gear with a feeler gauge.
(0.0043 in–0.0094 in)
Limit : 0.35mm (0.0138 in)
051RS002
Body (14) and Gears (10, 11)

The pump assembly must be replaced if one or more of
the conditions below is discovered during inspection.
D Badly worn or damaged driven gear (10).
D Badly worn drive gear (11) driving face.
D Badly scratched or scored body sliding face (14) or
driven gear (10). 051RS003
D Badly worn or damaged gear teeth. D Measure the side clearance with a precision straight
Measure the clearance between the body and the driven edge and a feeler gauge.
gear with a feeler gauge. Clearance
Standard : 0.10 mm–0.18 mm Standard : 0.03 mm–0.09 mm
(0.0039 in.–0.0070 in) (0.0011 in–0.0035 in)
Limit : 0.20mm (0.0079 in) Limit : 0.15mm (0.0059 in)
6. Install the plug (6).
051RS005
Oil Strainer
Check the oil strainer for cracking and scoring. If cracking 051RS007
and scoring are found, the oil strainer must be replaced. 7. Install oil pump assembly (5).
D Carefully remove any oil from the cylinder body and
the pump. Apply sealant (TB–1207B or equivalent)
to the pump fitting face as shown in illustration. Take
care that sealant is not applied to oil port surfaces.
The oil pump assembly must be installed within 5
minutes after sealant application before the sealant
hardens.
CAUTION: Do not apply an excessive amount of
sealant to the contact surface. Applying too much
sealant will overflow the contact surfaces. This
could cause serious damage to the engine.
D Attach oil pump assembly to cylinder body.
D Tighten the oil pump fixing bolts.
Torque : 25 N·m (18 lb·ft)
051RS006
Reassembly
1. Install drive gear (11).
2. Install driven gear (10).
3. Install oil pump cover (9) and first, loosely tighten all of
the attaching screws. Next, tighten the attaching
screws to the specified torque.
After installation, check that the gear rotates
smoothly.
4. Install relief valve (8) and apply engine oil to the relief
valve and spring (7).
5. Install spring (7). 051RW002
051RW001
Legend
(1) Around Bolt Holes
013RW010
(2) Around Dowel Pin 12. Install crankshaft timing pulley.
8. Install the new oil seal (12). Apply engine oil to the oil
seal lip before installation then use J–39202 oil seal
Installer, install oil seal.
015RS001
9. Install oil strainer (4) with O-ring (13).

10. Install oil pipe (3) with O-ring (13).
11. Install crankcase with oil pan (2).
D Remove oil on crankcase mounting surface and dry
the surface.
D Apply a proper 4.5 mm (0.7 in) wide bead of sealant
(TB1207C or equivalent) to the crankcase
mounting surface. The bead must be continuous.
D The crankcase must be installed within 5 minutes
after sealant application before the sealant
hardens.
Oil Pan and Crankcase

Removal
2. Lift vehicle by supporting the frame.
3. Remove under cover.
4. Drain engine oil.
5. Remove front wheels.
6. Remove oil level dipstick from level gauge tube.
7. Remove radiator under fan shroud.
8. Remove suspension cross member fixing bolts, 2 pcs
each per side and remove suspension cross member.
9. Remove pitman arm and relay lever assembly, using
the J-29107 remover, remove pitman arm from the
steering unit and remove four fixing bolts for relay
lever assembly.
10. Remove axle housing assembly four fixing bolts from
housing isolator side and mounting bolts from wheel
side. At this time support the axle with a garage jack 013RS003
and remove axle housing assembly. (For 4×4)
11. Remove starter fixing bolts.
Installation
12. Remove oil pan fixing bolts.
13. Remove oil pan, using J-37228 sealer cutter, remove 1. Install crankcase.
oil pan. A. Remove residual sealant, lubricant and moisture
from mounting surface, then dry thoroughly.
B. Properly apply a 4.5 mm (0.7 in) wide bead of
sealant (TB-1207C or equivalent) to mounting
surface of crankcase.
Sealant beat must be continuous.
D The crankcase must be installed within 5 minutes
after sealant application before the sealant
hardens.
013RS003
14. Remove crankcase fixing bolts.

15. Remove crankcase, using J-37228 sealer cutter,
remove crankcase.
NOTE: Do not deform or damage the flange of oil pan and
crankcase.
Replace the oil pan and/or crankcase if deformed or dam-
aged.
013RW010
C. Install crankcase, tighten crankcase fixing bolts to 3. Install starter and tighten fixing bolts.
the specified torque. Torque: 40 N·m (30 lb ft)
Torque : 10 N·m (89 lb in) 4. Install axle housing assembly and tighten fixing bolts
to the specified torque. (For 4×4)
Axle case bolts
Mounting bolts
013RW004
2. Install oil pan

1. Remove residual sealant, lubricant and moisture
from mounting surface, then dry thoroughly.
2. Properly apply a 4.5 mm (07 in) wide bead of
sealant (TB-1207C or equivalent) to mounting
surface of oil pan. 013RW005
5. Install relay lever assembly and tighten fixing bolts.

Sealant beat must be continuous.
D The crankcase must be installed within 5
minutes after sealant application befor the 6. Engage teeth of pitman arm and steering unit, and
sealant hardens. tighten nut to the specified torque.
013RW003
3. Install oil pan, tighten oil pan fixing bolts to the 013RW006
specified torque.
Legend
Torque : 25 N·m (18 lb ft) (1) Pitman Arm
(2) Relay Lever
7. Install suspension cross member and tighten fixing
013RW007
8. Install radiator under fan shroud.

9. Install under cover.
10. Install engine oil level dipstick.
11. Fill engine oil until full level on engine oil gauge
dipstick.
Oil Pump
Removal D Use J-39202 installer when installing new oil seal.
1. Disconnect battery ground cable. D Apply engine oil to oil seal lip.
2. Drain engine oil. D Install oil pump assembly to the cylinder block.
3. Remove crankcase assembly. NOTE: Do not damage oil seal during installation of oil
D Refer to removal procedure for Oil Pan and pump assembly.
this manual.
manual.
6. Remove timing pulley from crankshaft.
7. Remove four fixing bolts from oil filter assembly.
8. Remove oil strainer fixing bolts, remove oil strainer
assembly with O-ring.
9. Remove three bolts from oil pipe and O-ring.
10. Remove eight oil pump fixing bolts, then oil pump
assembly.
11. Remove sealant from mounting surface of oil pump
assembly, cylinder block and take care not to damage
mounting surfaces of oil pump and cylinder block.
015RS001
Installation D Tighten fixing bolts to the specified torque.

1. Install oil pump assembly Torque : 25 N·m (18 lb ft)
D Apply sealant (TB-1207B or equivalent) to the oil
pump mounting surfaces as shown in the
illustration.
D The oil pump assembly must be installed within 5
minutes after sealant application before the sealant
hardens.
NOTE: Do not apply sealant to the oil ports.
051RW001
2. Install oil pipe with O-ring, tighten fixing bolt to the

specified torque.
3. Install oil strainer with O-ring, tighten fixing bolt to the
specified torque.
051RW002
4. Install oil filter assembly and tighten bolts to the
specified torque.
050RW001
Legend
(1) Oil Pump
(2) Oil Filter
(3) Oil Gallery
(4) From Oil Filter
(5) To Oil Filter
5. Install timing pulley on crankshaft.

Install timing belt.
manual.
D Refer to install procedure for Crankshaft Pulley in
this manual.
7. Install crankcase assembly.
D Refer to installation procedure for Oil Pan and
8. Refill engine oil until full level on engine oil dipstick.
Oil Pump Oil Seal

Removal
this manual.
manual.
5. Remove timing pulley from crankshaft.
6. Remove oil pump oil seal using a sealer puller.
NOTE: Take care not to damage sealing surfaces of oil
pump and crankshaft when removing oil seal.
Installation
1. Install oil pump oil seal, apply engine oil to oil seal lip,
then install oil seal using J-39202 installer.
015RS001
2. Install timing pulley to crankshaft.

manual.
D Refer to installation procedure for Crankshaft
Pulley in this manual.
5. Refill engine oil until full level.
Oil Filter
Removal
3. Remove oil filter using J-36390 filter wrench.
Installation
1. Clean filter fitting surface and apply small amount of
engine oil to sealing surface.
2. Install oil filter cartridge by hand until it comes in
contact with sealing surface then rotate additional 2/3
turn to tighten using J-36390 filter wrench.
050RW001
Legend
(1) Oil Pump
(2) Oil Filter
(3) Oil Gallery
(4) From Filter
(5) To Filter
3. Fill engine oil until full level on dipstick.

4. Reconnect battery ground cable.
Main Data and Specification

Specifications
Item
6VE1
Oil capacity 5.3 liters
Crankcase, Oil pan, Timing belt tensioner, Timing pulley, timing belt cover, Oil pump, Oil gallery, Oil strainer
E06RW025
ENGINE SPEED CONTROL SYSTEM 6H–1
TROOPER
ENGINE
ENGINE SPEED CONTROL SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 6H–1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6H–2
Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . 6H–2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6H–2
Accelerator Pedal and Associated Parts . . 6H–2

systems.
6H–2 ENGINE SPEED CONTROL SYSTEM
Accelerator Pedal
Accelerator Pedal and Associated Installation
Parts 1. Install Accelerator pedal assembly (2).
2. Connect AP sensor (1) harness connector.
101RY00006
Legend
(1) Accelerator Position Sensor
Removal
2. Disconnect Accelerator position (AP) sensor (1)
connector from Accelerator pedal assembly.
3. Remove Accelerator pedal assembly (2).
INDUCTION 6J–1
TROOPER
ENGINE
INDUCTION
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 6J–1
Air Cleaner Element . . . . . . . . . . . . . . . . . . . . . 6J–2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6J–2
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6J–2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6J–2
Service Precaution
systems.
6J–2 INDUCTION
Air Cleaner Element

1. Remove positive ventilation hose connector(1). 1. Install air cleaner element(5).
2. Remove intake air temperature sensor(2). 2. Attach the air cleaner duct cover to the body
3. Remove air flow sensor(3). completely, then clamp it with the clip(4).
4. Remove air cleaner duct assembly(4). 3. Install mass air flow sensor(3).
5. Remove air cleaner element(5). 4. Install air temperature sensor(2).
5. Install positive crankcase ventilation hose
connector(1).
130RW003
Inspection 130RW003
Check the air cleaner filter for damage or dust clogging.

Replace if it is damaged, or clean if it is clogged.
Cleaning Method
Tap the air cleaner filter gently so as not to damage the
paper filter, or clean the element by blowing with
compressed air of about 490 kPa (71 psi) from the clean
side if it is extremely dirty.
130RW002
AUTOMATIC TRANSMISSION (4L30–E) 7A–1
TROOPER
TRANSMISSION
CONTENTS
Automatic Transmission (4L30–E) . . . . . . . . . 7A
Transmission Control System (4L30–E) . . . . 7A1
Manual Transmission . . . . . . . . . . . . . . . . . . . . 7B
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C
AUTOMATIC TRANSMISSION (4L30–E)

CONTENTS
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–3 Valve Body Assembly (Main Case) . . . . . . . . 7A–40
Range Reference Chart . . . . . . . . . . . . . . . . . . 7A–4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–40
Normal Operation Of 2000 4L30–E Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–40
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–5 Valve Body Assembly (Adapter Case) . . . . . . 7A–41
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–41
Driver Information . . . . . . . . . . . . . . . . . . . . . . . 7A–5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–41
General Diagnosis Procedure . . . . . . . . . . . . . 7A–8
Powertrain Control Module (PCM) . . . . . . . . . 7A–41
Preliminary Inspection Chart . . . . . . . . . . . . . . 7A–9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–41
Checking Transmission Fluid Level and
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–41
Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–10
Test Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–11 Speed Sensor (Extension Housing) . . . . . . . . 7A–42
Mechanical / Hydraulic Diagnosis Check Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–42
Trans Indicator Chart . . . . . . . . . . . . . . . . . . . . 7A–12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–42
Mechanical / Hydraulic Diagnosis Transmission Oil Temperature Sensor
Symptoms Index . . . . . . . . . . . . . . . . . . . . . . . . 7A–13 (Main Case) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–42
Stall Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–23 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–42
Line Pressure Test . . . . . . . . . . . . . . . . . . . . . . 7A–23 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–42
Shift Speed Chart . . . . . . . . . . . . . . . . . . . . . . . 7A–24 Front Oil Seal (Converter Housing) . . . . . . . . 7A–43
Lockup Speed Chart . . . . . . . . . . . . . . . . . . . . . 7A–26 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–43
Changing Transmission Fluid . . . . . . . . . . . . . 7A–27 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–43
Selector Lever . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–27 Rear Oil Seal (Extension Housing) . . . . . . . . . 7A–43
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–27 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–43
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–28 Transmission (4L30–E) . . . . . . . . . . . . . . . . . . 7A–44
Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–29 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–44
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–29 Converter Housing And Oil Pump Assembly 7A–58
Transmission (With Transfer Case Disassembled View . . . . . . . . . . . . . . . . . . . . 7A–58
/ Extension Assembly) . . . . . . . . . . . . . . . . . . . 7A–31 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–58
Transmission And Associated Parts . . . . . . 7A–31 Inspection And Repair . . . . . . . . . . . . . . . . . . 7A–58
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–33 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–59
Solenoid (Main Case Valve Body) . . . . . . . . . 7A–38 Disassembled View . . . . . . . . . . . . . . . . . . . . 7A–59
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–38 Inspection And Repair . . . . . . . . . . . . . . . . . . 7A–60
Solenoid (Adapter Case Valve Body) . . . . . . . 7A–39 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–60
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–39 Main Case Valve Body . . . . . . . . . . . . . . . . . . . 7A–61
7A–2 AUTOMATIC TRANSMISSION (4L30–E)
Disassembled View . . . . . . . . . . . . . . . . . . . . 7A–61 Reverse Clutch Piston And Center Support . 7A–74
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–61 Disassembled View . . . . . . . . . . . . . . . . . . . . 7A–74
Inspection And Repair . . . . . . . . . . . . . . . . . . 7A–62 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–74
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–62 Inspection And Repair . . . . . . . . . . . . . . . . . . 7A–75
Adapter Case Valve Body . . . . . . . . . . . . . . . . 7A–63 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–75
Disassembled View . . . . . . . . . . . . . . . . . . . . 7A–63 Overrun Clutch And Turbine Shaft . . . . . . . . . 7A–76
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–63 Disassembled View . . . . . . . . . . . . . . . . . . . . 7A–76
Inspection And Repair . . . . . . . . . . . . . . . . . . 7A–63 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–77
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–63 Inspection And Repair . . . . . . . . . . . . . . . . . . 7A–77
Third Clutch And Sprag Unit . . . . . . . . . . . . . . 7A–65 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–77
Disassembled View . . . . . . . . . . . . . . . . . . . . 7A–65 Main Data And Specification . . . . . . . . . . . . . . 7A–79
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–65 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–83
Inspection And Repair . . . . . . . . . . . . . . . . . . 7A–65 4L30–E Parts List . . . . . . . . . . . . . . . . . . . . . . . 7A–86
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–66 Extension Housing Assembly Oil Seal . . . . . . 7A–94
Third Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–67 Extension Housing Assembly Rear Oil Seal
Disassembled View . . . . . . . . . . . . . . . . . . . . 7A–67 and Associated Parts . . . . . . . . . . . . . . . . . . 7A–94
Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–67 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–94
Inspection And Repair . . . . . . . . . . . . . . . . . . 7A–67 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–94
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–67 Extension Housing Assembly . . . . . . . . . . . . . 7A–96
Sprag Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–69 Extension Housing Assembly and
Disassembled View . . . . . . . . . . . . . . . . . . . . 7A–69 Associated Parts . . . . . . . . . . . . . . . . . . . . . . 7A–96
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–69 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–97
Inspection And Repair . . . . . . . . . . . . . . . . . . 7A–69 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–97
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–69 Extension Housing Assembly . . . . . . . . . . . . . 7A–99
Second Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–70 Extension Housing Assembly and
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–100
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–70
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–100
Inspection And Repair . . . . . . . . . . . . . . . . . . 7A–71
Extension Housing Assembly . . . . . . . . . . . 7A–102
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–71
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–103
3–4 Accumulator Piston . . . . . . . . . . . . . . . . . . 7A–72
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–103
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–72
Inspection And Repair . . . . . . . . . . . . . . . . . . 7A–73
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–106
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7A–73

systems.
Construction
A07RS001
Legend (7) Third Clutch (C3)

(1) Torque Converter Clutch (TCC) (8) Ravigneaux Planetary Gear Set
(2) Fourth Clutch (C4) (9) Brake Band (B)
(3) Overrun Clutch (OC) (10) Overdrive Free Wheel (One Way Clutch)
(4) Overdrive Unit (OFW)
(5) Reverse Clutch (RC) (11) Principle Sprag Assembly (One Way Clutch)
(6) Second Clutch (C2) (PFW)
Range Reference Chart
C07RY00032
Normal Operation Of 2000 4L30–E Diagnosis

Transmission Introduction
Torque Converter Clutch (Electronically The systematic troubleshooting information covered by
Controlled Capacity Clutch : ECCC) this Section offers a practical and systematic approach to
diagnosing 4L30–E transmission, using information that
Application Conditions: can be obtained from road tests, electrical diagnosis, oil
The clutch apply is controlled by moving the converter pressure checks or noise evaluation.
clutch control valve by commanding Torque Converter The key to correcting a complaint is to make use of all of
Clutch (TCC) solenoid using the PWM signal. the available symptoms and logically letting them direct
The TCC is normally applied in 2nd, 3rd and 4th gears you to the cause.
only when all of the following conditions exist: When dealing with automatic transmission complaints, it
— The engine coolant temperature is above 70°C is best to gather as many symptoms as possible before
(158°F) and ATF temperature is above 18°C making the decision to remove the transmission from the
(64.5°F). vehicle.
— The brake pedal is released. Frequently, the correction of the complaint does not
— The shift pattern requests TCC apply. require removal of the transmission from the vehicle.
Moreover, TCC is always applied in 2nd, 3rd and 4th
gears when the transmission oil temperature is above Driver Information
135°C (275°F). To analyze the problem fill out a complete description of
This mode should be canceled at 125°C (257°F). the owner’s complaint.
Please draw a circle around the right information and
ATF Warning Lamp complete the following form. (The next page is an
The ATF warning lamp will be constantly on (not flashing) example of a completed form). You can draw a circle
if the transmission oil temperature is above 145°C around many numbers if you are not sure.
(293°F).
The ATF warning lamp goes off again when the
transmission oil temperature is below 125°C (257°F).
Reverse Lock Out

With the selector lever in reverse position, the PCM will
not close the PWM solenoid until the vehicle is below 11
km/h (6.8 mph), thus preventing reverse engagement
above this speed.
F07RT036
Example of form completed.

F07RT037
General Diagnosis Procedure
F07RT038
Preliminary Inspection Chart
F07RY00001
Checking Transmission Fluid Level NOTE: Check transmission fluid temperature with scan
tool.
and Condition Minimum fluid level → 57°C (135°F)
Checking fluid level and condition (color and odor) at Maximum fluid level → 32°C (90°F)
regular intervals will provide early diagnosis information
about the transmission. This information may be used to
correct a condition that, if not detected early, could result
in major transmission repairs.
IMPORTANT: When new, automatic transmission fluid
is red in color. As the vehicle is driven, the transmission
fluid will begin to look darker in color. The color may
eventually appear light brown.
A dark brown color with burnt odor may indicate
excessive fluid deterioration and signal a need for fluid
change.
Fluid Level
When adding or changing fluid, use only DEXRON –III.
Refer to Maintenance and Lubrication in General
Information section for maintenance information and
servicing interval.
CAUTION: DO NOT OVERFILL.
Overfilling will cause foaming, loss of fluid, abnor-
mal shifting and possible damage to the transmis-
242RW003
sion.
CAUTION: Do not open overfill screw with engine
1. Park the vehicle on level ground and apply the parking stopped.
brake firmly.
2. Check fluid level with engine running at idle. CAUTION: DO NOT CHECK FLUID LEVEL UNDER
THESE CONDITIONS:
NOTE: Be sure that transmission fluid temperature is D Immediately after driving at sustained highway
below 30°C (86°F). speeds.
3. Move the selector lever through all gear ranges. D In heavy city traffic during hot weather.
4. Move the selector lever to “Park”. D If vehicle is towing a trailer.
5. Let engine idle for 3 minutes and open the overfill If the vehicle has been operated under these conditions,
screw (1). shut the engine off and allow the vehicle to “cool” for thirty
6. Add released transmission fluid until it flows out over (30) minutes. After the cool down period, restart the
the overfill screw opening. vehicle and continue from step 2 above.
7. Let engine idle until a fluid temperature between 32°C
(90°F) and 57°C (135°F) is reached, then close the
overfill screw (1).
Torque: 38 N•m (28 lb ft)
NOTE: To prevent fluid leaks, the overfill screw and oil
drain screws gasket must be replaced each time these
screws are removed.
Fluid Condition
FLUID CONDITION
NORMAL* CONTAMINATED
RED OR LIGHT NON–TRANSPARENT
COLOR BROWN BROWN
BROWN / PINK
DRAIN
NO YES YES YES
REQUIRED?
CONTAMINA– NONE Very small amount of Contamination by Large pieces of metal
TION foreign material in coolant or other source or other foreign
bottom of pan material in bottom of
pan
1. LOW LEVEL: – Remove both pans – Repair/replace – Transmission
A. Add fluid to – Change filter radiator cooler overhaul required
obtain proper – Flush cooler – Transmission – Flush cooler and
level & check for overhaul required cooler lines
– Add new fluid
external leaks. – Check for: – Add new fluid
CORRECT – Check level
B. Correct cause of D Damaged plates – Check level
LEVEL AND leak. and seals
CONDITION 2. HIGH LEVEL: D Contaminated
– Remove excess solenoids
fluid – Flush cooler
– Add new fluid
– Check level
*Fluid should be changed according to maintenance D If the lamp stays ON or stays OFF, GOTO “Check
schedule. Trans” Check in Transmission Control System
(4L30–E) section.
Test Driving
2. Drive the vehicle. During the test drive, be sure that
Some 4L30–E automatic transmission complaints will the transmission achieves normal operating
require a test drive as a part of the diagnostic procedure. temperature (approx. 20 minutes).
Some codes will not set unless the vehicle is moving. The Allow the transmission to go through all of its gear
purpose of the test drive is to duplicate the customer’s ranges, checking shift timing and firmness. Duplicate
complaint condition and set a current Powertrain Control the owner ’s complaint condition as closely as
Module (PCM) trouble code. Perform this procedure possible during the test drive.
before each 4L30–E automatic transmission repair, and
again after repairs are made. 3. If, during the test drive, the “CHECK TRANS” lamp
IMPORTANT: comes on, use the scan tool to check for trouble
codes.
D Duplicate the condition under which the customer’s 4. If, during the test drive, a problem is felt, but the
complaint was observed. “CHECK TRANS” lamp does not come on and no
D Depending on the complaint, the line pressure gauge trouble codes are present, drive the vehicle with the
and the scan tool may be required during the test PCM disconnected (manually shifting the vehicle).
drive. D In Manual L, the vehicle operates in first gear.
D During the test drive, it is important to record all
necessary data from the areas being monitored, for D In Manual 2, the vehicle operates in third gear.
use in diagnosis. Also listen for and note any unusual D In Manual 3 or “D”, the vehicle operates in fourth
noises. gear.
The following procedure should be used to test drive If the problem still exists with the PCM disconnected,
4L30–E automatic transmission complaint vehicles: refer to Mechanical/Hydraulic Diagnosis in this
1. Turn the ignition ON without starting the engine. section.
Check that the “CHECK TRANS” lamp comes on for 5. If no problem has been found at this point, check all
approximately 2 seconds and then goes out and underhood connections that supply power to the PCM
remains out. and ignition fuses. Physically and visually inspect all
D If the lamp is flashing, GOTO Check Trans Indicator the PCM harness connectors for loose or corroded
in Transmission Control System (4L30–E) section. terminals. Inspect the PCM ground points.
D If no serial data is present, GOTO OBD System
Check. Refer to Driveability and Emissions in
Engine section.
Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart

Perform Preliminary Inspection First!
F07RT013
When the “CHECK TRANS” indicator is flashing, it

indicates that a problem related to the transmission, the
Powertrain Control Module (PCM), or the vehicle harness
has occurred.
The system is now operating in a “BACKUP MODE”
where the risk of further damaging the transmission has
been reduced. The vehicle may be shifted manually.
If the initial problem is intermittent or seldom, switching
the engine OFF/ON might allow normal operation again
until the problem reoccurs.
Mechanical / Hydraulic Diagnosis Symptoms Index

Perform Preliminary Inspection First!
CHART SYMPTOMS
1 NO ENGINE START IN NEUTRAL OR PARK
2 NO FORWARD GEARS IN ANY RANGE/NO REVERSE
3 NO ENGINE BRAKE IN ANY RANGE
4 POOR SHIFTING IN ALL GEARS (ALL HARSH OR ALL SOFT)
5a DELAYS IN DRIVE AND REVERSE
5b DELAYS IN REVERSE ONLY
6 DIAGNOSTIC TROUBLE CODE (DTC) P0730
7 HARSH 1–2 SHIFT
8 HARSH 3–4 SHIFT
9a 3–2 DOWNSHIFT COMPLAINT
9b HARSH SHIFT WHEN SHIFTING INTO “D” OR ACCELERATING FROM STOP
9c COASTDOWN HARSH SHIFT OR CLUNK AT 3–2 DOWNSHIFT
10 INTERMITTENT 4TH TO 2ND GEAR DOWNSHIFT AT STEADY SPEED
11 ENGINE FLARE AT SHIFTING DURING TURNING ONLY (USUALLY WITH WARM ENGINE)
12 ENGINE FLARE DURING 1–2 OR 2–3 SHIFT
13 SHUDDER ONLY DURING TORQUE CONVERTER CLUTCH (TCC) APPLYING
14 POSSIBLE CAUSES OF TRANSMISSION NOISE
15a POSSIBLE CAUSES OF LOW LINE PRESSURE
15b POSSIBLE CAUSES OF HIGH LINE PRESSURE
16 POSSIBLE CAUSES OF TRANSMISSION FLUID LEAKS
NOTE: Numbers with parenthesis on the following charts

refer to Parts List at end of this section.
Chart 1: No Engine Start In Neutral Or Park

Step Action Yes No
1 Does engine start when shift lever moved from drive to neutral
mostly in hot condition? Go to Step 2 Go to Step 3
2 Does engine start in park at any condition? Re–test vehicle Go to Step 4
3 Does engine also not start in neutral when shift lever moved from
park to neutral? Go to Step 4 Go to Step 5
4 Check mode switch (63) setting. Readjust if necessary.
Problems fixed? Re–test vehicle Go to Step 5
5 Check start circuit of mode switch (63) open in neutral.
Locate and repair Replace mode
Was open found? open(s) switch (63)
Chart 2: No Forward Gears In Any Range/No Reverse

Step Action Yes No
1 Check line pressure. Refer to Line Pressure Test in this section. Use Chart 15a:
Possible Causes
Was line pressure normal?
of Low Line
Pressure in this
Go to Step 2 section
2 1. Check internal linkage:
– Manual linkage (58) not moving manual valve (326).
2. Check for internal mechanical damage:
– Turbine shaft (506) broken loose.
– Overrun roller clutch (516) broken loose.
Was the problem found? Repair or replace —
Chart 3: No Engine Brake In Any Range

Step Action Yes No
Possible Causes
of Low Line
Pressure in this
2 1. Check for overrun clutch leaks caused by:
– Damaged piston lip (513)
– Check ball defective (504)
2. Check for overrun lockout valve (705) stuck by foreign
material.
3. Check for leaks at turbine shaft (506) caused by:
– Teflon seal rings damaged (508)
– Excessive wear of turbine shaft bearing surfaces.
Chart 4: Poor Shifting In All Gears (All Harsh Or All Soft)
Step Action Yes No
1 Check line pressure. Refer to Line Pressure Test in this section.
Was line pressure normal? Go to Step 2 Go to Step 3
2 1. Check for these conditions which could affect clutch apply
time:
– Defective band apply solenoid (323).
– Defective servo or/and accumulator piston.
– Excessive clutch piston travel.
2. Check of possible causes of internal leaks:
– Cut or damaged sealing ring(s)
– Damaged sealing gasket(s)
– Check ball missing or out of location in 2nd and 3rd clutch
pistons.
3. Check for causes of burned clutch plates or band.
3 Was the line pressure high? Use Chart 15a:
Possible Causes
of Low Line
Pressure in this
4 Does DTC P0705 set? Use Chart 15b:
Possible Causes
of High Line
Diagnose those Pressure in this
DTC(s) first section
Chart 5a: Delays In Drive And Reverse

NOTE: A short delay (less than 3 seconds) when first
engaging drive or reverse after allowing vehicle to sit
overnight is normal.
Step Action Yes No
1 Check line pressure. Refer to Line Pressure Test in this section. More than 3
second delay in
drive and reverse
with engine off 1 Use Chart 15a:
hour or less. Possible Causes
Teflon seals (508) of Low Line
on turbine shaft Pressure in this
damaged. Repair section.
Chart 5b: Delays In Reverse Only

Step Action Yes No
Possible Causes
of Low Line
Pressure in this
Go to Step 2 section.
2 Main case valve body gasket (88) damaged.
– Reverse check ball (85) in valve body (84) missing or out of
location.
– Check for restrictions at valve body transfer plate orifice.
Was the problem found? Repair —
Chart 6: Diagnostic Trouble Code (DTC) P0730

Step Action Yes No
1 Check line pressure. Refer to Line Pressure Test in this section. Use Chart 15b:
Possible Causes
of High Line
Pressure in this
2 1. 1st and 2nd gear missing or 3rd and 4th gear missing.
Check appropriate shift valve. If OK replace solenoid.
2. No engine brake in any range (All ranges in Drive and Reverse
are OK).
Check for suspected conditions modifying delays to clutch
apply:
– Overrun clutch seal damaged.
– Excessive overrun clutch piston travel.
– Defective 3–4 accumulator piston.
– Causes of internal leaks.
– Causes of burned clutch plates.
3. 1st and 4th gear missing or 2nd and 3rd gear missing.
Shift solenoid A stuck. Replace shift solenoid A.
4. DTC P0730 is set in D range 1st gear above 3500 rpm.
Go to Step 3.
5. DTC P0730 is set in D range 3rd gear between 55-80 mph.
NOTE: Perform this test within safe and legal limits.
Check for suspected conditions modifying delays to clutch
apply:
– 4th clutch seal damaged.
– Excessive 4th clutch piston travel.
– Defective 3–4 accumulator piston.
3 Check 3rd gear in “D” in winter mode. Shift solenoid A
stuck. Replace
Does vehicle move?
shift solenoid A. Go to Step 4
4 Check for suspected conditions modifying delays to clutch apply:
– 2nd clutch seal damaged.
– Excessive 2nd clutch piston travel.
– Defective accumulator piston.
– Check ball missing or out of location in 2nd clutch.
– Seals cut, damaged or missing.
– Gaskets defective.
Chart 7: Harsh 1–2 Shift
Step Action Yes No
1 Check line pressure. Refer to Line Pressure Test in this section. Check for 1–2
accumulator Use Chart 15b:
Was line pressure normal? Possible Causes
valve (320) stuck
by foreign of High Line
material in main Pressure in this
case valve body. section.
Chart 8: Harsh 3–4 Shift

Step Action Yes No
Possible Causes
of High Line
Pressure in this
2 1. Check for 3–4 accumulator valve (407) stuck in adapter case
valve body (401).
2. Check for 3–4 accumulator piston (18) stuck in adapter case
(20).
Chart 9a: 3–2 Downshift Complaint

Step Action Yes No
Possible Causes
of Low Line
Pressure in this
2 Does DTC P1850 set? Replace band
Diagnose P1850 apply solenoid
first (PWM) (323)
Chart 9b: Harsh Shift When Shifting Into “D” Or Accelerating From Stop
Step Action Yes No
Possible Causes
of High Line
Pressure in this
first (PWM) (323)
Chart 9c: Coastdown Harsh Shift Or Clunk At 3–2 Downshift

Step Action Yes No
Possible Causes
of High Line
Pressure in this
first (PWM) (323)
Chart 10: Intermittent 4TH TO 2ND Gear Downshift At Steady Speed

Step Action Yes No
1 Check for consistent speed sensor reading with scan tool. Replace mode
switch for
Was the reading correct?
intermittent
contact. Go to Step 2
2 1. Check for wiring harness damage or short to ground. If OK, go
to (2).
2. Check transmission speed sensor connections. If OK, go to
(3).
3. Replace transmission speed sensor.
Replace speed
Was the replacement complete? — sensor.
Chart 11: Engine Flare At Shifting During Turning Only (Usually With Warm Engine)
Step Action Yes No
1 Check for oil leaks at transmission. Replace
transmission oil
Was the problem found?
filter and gasket —
Chart 12: Engine Flare During 1–2 Or 2–3 Shift

Step Action Yes No
Possible Causes
of Low Line
Pressure in this
2 1. Check for a stuck 1–2 accumulator valve (320).
2. Check for servo piston (106) leaks.
3. Check for a stuck band apply solenoid (323).
Was line pressure normal? Repair or replace —
Chart 13: Shudder Only During Torque Converter Clutch (TCC) Applying
Step Action Yes No
1 1. TCC shudder is one of the most commonly misdiagnosed
conditions in an automatic transmission. The key to
diagnosing TCC shudder is to note when it happens and under
what conditions. Once the TCC has been fully applied, it is
nearly impossible to make it shudder. TCC shudder (short
burst of noise normally less than 1 second) will only occur
during clutch applying. It is not a steady state condition.
2. Drive until whole drivetrain is at normal operating temperature.
– On 4WD vehicles, the test must be performed with transfer
case selector lever in “2H” position. Replace
– Shudder is a short burst of noise normally less than 1 second transmission fluid
in duration, and can be induced by the following maneuver: and filter (remove
both pans) and
3. From coast condition at 50 mph in “D” range (Normal mode),
flush cooler lines.
depress the throttle to 1/4-1/3 throttle. If present, shudder will
Replace Perform
occur within 5 seconds together with TCC application.(The
converter mechanical
scan tool may be used to determine the exact time of TCC
assembly and inspection of
applying)
O-ring on turbine other drivetrain
Was the problem found? shaft components.
Chart 14: Possible Causes Of Transmission Noise

CAUTION: Before checking transmission for what
is believed to be transmission noise, ensure
presence and positioning of insulating plugs, pads
etc. Also make sure that noise does not come from
other drivetrain components.
Whine or Buzz Oil level low Fill with ATF, check for external
leaks.
Plugged or restricted oil filter Inspect oil filter.
Replace oil filter or ATF as necessary.
Damaged oil filter gasket Replace oil filter gasket.
Knocking noise from front of Loose bolts (Converter to flex plate) Tighten to specifications.
transmission
transmission.
Cracked or broken flex plate Replace flex plate.
Converter damaged Replace converter.
Knocking noise while driving, mostly Transmission mount loose or broken Tighten mount bolts or replace
on acceleration. transmission mount.
Cooler line mounts loose or broken Tighten or replace cooler line
mounts.
Cooler lines touching body or frame Repair or replace as necessary.
Knocking noise when vehicle is Loose flex plate mounting bolts Tighten to specifications.
stationary
stationary.
Cracked or broken flex plate Replace flex plate.
Damaged converter Replace converter.
Chart 15a: Possible Causes of Low Line Pressure

Step Action Yes No
1 Check oil level.
Was the problem found? Fill with ATF Go to Step 2
2 Check for defective throttle position sensor.
Replace throttle
Was the problem found? position sensor Go to Step 3
3 Check for plugged, loose, or damaged oil filter (79). Inspect oil filter,
tighten bolts or
replace oil filter
(79) Go to Step 4
4 Check for a stuck force motor plunger (404). (Adapter case valve
Replace force
body)
motor plunger
Was the problem found? (404) Go to Step 5
5 Check for a stuck feed limit valve (412). (Adapter case valve body)
Replace feed limit
Was the problem found? valve (412) Go to Step 6
6 Check for loose converter bolts (4 & 5).
Tighten converter
Was the problem found? bolts (4 & 5) Go to Step 7
7 Check for a stuck pressure regulator valve (217). (Oil pump) Replace pressure
regulator valve
(217) Go to Step 8
8 Check for a stuck boost valve (213).(Oil pump)
Replace boost
9 Check for blocked intermediate oil passages to pressure
regulator valve. (Oil pump)
Was the problem found? Replace oil pump Go to Step 10
10 Check for defective oil pump (9, 201, 202 & 228).
Was the problem found? Replace oil pump Go to Step 11
11 Check for internal leaks.
– Check balls missing or out of location in valve bodies Install balls, or
correct ball
– Seals cut or damaged location
– Gaskets defective, etc. Replace seals
Was the problem found? Replace gaskets —
Chart 15b: Possible Causes Of High Line Pressure
NOTE: If transmission is operating in backup mode, high
line pressure will be present.
Step Action Yes No
1 Check for defective throttle position sensor.
Replace throttle
Was the problem found? position sensor. Go to Step 2.
2 Check for a stuck force motor plunger (404). (Open
Replace force
circuit/intermittent) (Adapter case valve body)
motor plunger
Was the problem found? (404) Go to Step 3
3 Check for a stuck feed limit valve (412). (Adapter case valve body) Replace force
motor plunger
(412) Go to Step 4
4 Check converter bolts (4 & 5).
Tighten converter
Was the problem found? bolts (4 & 5) Go to Step 5
5 Check for a stuck pressure regulator valve (217). (Oil pump) Replace pressure
regulator valve
(217) Go to Step 6
6 Check for a stuck boost valve (213). (Oil pump)
Replace boost
7 Check for internal leaks.
– Check balls missing or out of location in valve bodies Install balls, or
correct ball
– Seals cut or missing location
– Gaskets defective, etc. Replace seals
Was the problem found? Replace gaskets —
Chart 16: Possible Causes Of Oil leaks around the engine and transmission are gener-
Transmission Fluid Leaks ally carried toward the rear of the vehicle by the air
stream. In determining the source of an oil leak, the fol-
Before attempting to correct an oil leak, the actual source lowing two checks should be made:
of the leak must be determined. In many cases, the
1. With the engine running, check for external line
source of the leak may be difficult to determine due to
pressure leaks.
“wind flow” around the engine and transmission.
The suspected area should be wiped clean before in- 2. With the engine off, check for oil leaks due to the
specting for the source of the leak. raised oil level caused by drainback of converter oil
into the transmission.
Possible Causes Of Fluid Leaks Due To Sealing Malfunction
240RX008
Legend (9) Oil Cooler Connectors (2)

(1) Electrical Connector (Main Case) Seal (10) Oil Pan Gasket (Adapter Case)
(2) Transmission Vent (Breather) (11) Converter housing attaching bolts not correctly
(3) Speed Sensor O–Ring torqued
(4) Extension (Adapter) Lip Seal (12) Converter Housing Lip Seal
(5) Extension (Adapter) to Main Case Gasket (13) Line Pressure Tap Plug
(6) Overfill and Oil Drain Screws Gasket (14) Electrical Connector (Adapter Case) Seal
(7) Oil Pan Gasket (Main Case) (15) Adapter Case Seal Rings (2)
(8) Selector Shaft Seal
Stall Test
The stall test allows you to check the transmission for
internal abrasion and the one way clutch for slippage.
Torque converter performance can also be evaluated.
The stall test results together with the road test results will
identify transmission components requiring servicing or
adjustment.
Stall Test Procedure:
1. Check the level of the engine coolant, the engine oil,
and the automatic transmission fluid. Replenish if
necessary.
2. Block the wheels and set the parking brake.
3. Connect a tachometer to the engine.
4. Start the engine and allow it to idle until the engine
coolant temperature reaches 70 – 80°C (158 –
176°F).
5. Hold the brake pedal down as far as it will go.
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6. Place the selector in the “D” range.
4. Start the engine and allow it to idle until the engine
7. Gradually push the accelerator pedal to the floor. coolant temperature reaches 70 – 80°C (158 –
The throttle valve will be fully open. 176°F).
Note the engine speed at which the tachometer 5. Hold the brake pedal down as far as it will go.
needle stabilizes.
6. Place the selector in the “D” range.
Stall Speed : 2,100 ±150 rpm 7. Note the pressure gauge reading with the engine
NOTE: Do not continuously run this test longer than 5 idling.
seconds. 8. Gradually push the accelerator pedal to the floor. The
throttle valve will be fully open.
8. Release the accelerator pedal.
Note the pressure gauge reading with the accelerator
9. Place the selector in the “N” range. pedal fully depressed.
10. Run the engine at 1,200 rpm for one minute.
This will cool the transmission fluid. NOTE: Do not continuously run this test longer than 5
seconds.
11. Repeat Steps 7 – 10 for the “3”, “2”, “L” and “R”
ranges. 9. Release the accelerator pedal.
10. Place the selector in the “N” range.
Line Pressure Test 11. Run the engine at 1,200 rpm for one minute.
The line pressure test checks oil pump and control valve This will cool the transmission fluid.
pressure regulator valve function. It will also detect oil
12. Repeat Steps 7 – 11 for the “3”, “2”, “L”, and “R”
leakage.
ranges.
Line Pressure Test Procedure: 13. Install a pressure detection plug to the transmission
1. Check the level of the engine coolant, the engine oil, case, applying recommended thread locking agent
and the automatic transmission fluid. (LOCTITE 242) or its equivalent to thread of plug.
Replenish if required. Make sure that thread is cleaned before applying
locking agents.
2. Block the wheels and set the parking brake.
14. Tighten the pressure detection plug to the specified
3. Remove the pressure detection plug at the left side of torque.
the transmission case.
Torque: 9 – 14N·m (7 – 10lb ft)
Set J–29770–A pressure gauge and adapter to the
pressure detection plug hole.
LEVER LINE PRESSURE FORCE MOTOR

MODE ENGINE SPEED
POSITION kPa PSI CURRENT (mA)
NORMAL/POWER D,3,2,L IDLE 590 – 730 86 – 106 680 – 720
WINTER D IDLE 300 – 390 44 – 57 1,020 – 1,060
NORMAL/POWER
REVERSE IDLE 460 – 630 67 – 91 880 – 920
WINTER
NORMAL/POWER D, 3, 2, L STALL SPEED 1,250 – 1,380 181 – 200 70 – 110
WINTER D STALL SPEED 1,250 – 1,380 181 – 200 70 – 110
NORMAL/POWER
REVERSE STALL SPEED 1,400 – 1,580 203 – 229 340 – 380
WINTER
Shift Speed Chart

Transfer gear ratio: High: 1.000
Rear axle ratio: 4.300
“Normal mode”
Upshift
1→2 2→3 3→4
Throttle
Range (First Gear) (Second Gear) (Second Gear) (Third Gear) (Third Gear) (Fourth Gear)
opening
km/h (mph) km/h (mph) km/h (mph)
D Fully opened 53 ∼ 59 (33 ∼ 37) 110 ∼ 116 (68 ∼ 72) 166 ∼ 172 (103 ∼ 107)
(Drive) Half throttle 32 ∼ 38 (20 ∼ 24) 57 ∼ 63 (35 ∼ 39) 99 ∼ 105 (61 ∼ 65)
3 Fully opened 53 ∼ 59 (33 ∼ 37) 110 ∼ 116 (68 ∼ 72) —
(Third) Half throttle 32 ∼ 38 (20 ∼ 24) 57 ∼ 63 (35 ∼ 39) —
2 Fully opened 53 ∼ 59 (33 ∼ 37) — —
(Second) Half throttle 32 ∼ 38 (20 ∼ 24) — —
Downshift
1←2 2←3 3←4
Throttle
opening
Fully opened 45 ∼ 51 (28 ∼ 32) 87 ∼ 93 (54 ∼ 58) 155 ∼ 161 (96 ∼ 100)
D Half throttle 14 ∼ 20 (9 ∼ 12) 33 ∼ 39 (20 ∼ 24) 64 ∼ 70 (40 ∼ 43)
(Drive)
Fully closed 13 ∼ 19 (8 ∼ 12) 19 ∼ 25 (12 ∼ 16) 27 ∼ 33 (17 ∼ 21)
Fully opened 45 ∼ 51 (28 ∼ 32) 87 ∼ 93 (54 ∼ 58) —
3 Half throttle 14 ∼ 20 (9 ∼ 12) 33 ∼ 39 (20 ∼ 24) —
(Third)
Fully closed 13 ∼ 19 (8 ∼ 12) 19 ∼ 25 (12 ∼ 16) —
Fully opened 45 ∼ 51 (28 ∼ 32) 92 ∼ 98 (57 ∼ 61) —
2 Half throttle 14 ∼ 20 (9 ∼ 12) 92 ∼ 98 (57 ∼ 61) —
(Second)
Fully closed 13 ∼ 19 (8 ∼ 12) 92 ∼ 98 (57 ∼ 61) —
L
— 48 ∼ 54 (30 ∼ 34) — —
(First)
“Power mode”
Upshift
1→2 2→3 3→4
Throttle
opening
D Fully opened 53 ∼ 59 (33 ∼ 37) 110 ∼ 116 (68 ∼ 72) 174 ∼ 180 (108 ∼ 112)
(Drive) Half throttle 41 ∼ 47 (25 ∼ 29) 84 ∼ 90 (52 ∼ 56) 136 ∼ 142 (84 ∼ 88)
3 Fully opened 53 ∼ 59 (33 ∼ 37) 110 ∼ 116 (68 ∼ 72) —
(Third) Half throttle 41 ∼ 47 (25 ∼ 29) 84 ∼ 90 (52 ∼ 56) —
2 Fully opened 53 ∼ 59 (33 ∼ 37) — —
(Second) Half throttle 41 ∼ 47 (25 ∼ 29) — —
Downshift
1←2 2←3 3←4
Throttle
opening
Fully opened 45 ∼ 51 (28 ∼ 32) 104 ∼ 110 (65 ∼ 68) 163 ∼ 169 (101 ∼ 105)
D Half throttle 22 ∼ 28 (14 ∼ 17) 57 ∼ 63 (35 ∼ 39) 108 ∼ 114 (67 ∼ 71)
(Drive)
Fully closed 13 ∼ 19 (8 ∼ 12) 23 ∼ 29 (14 ∼ 18) 46 ∼ 52 (29 ∼ 32)
Fully opened 45 ∼ 51 (28 ∼ 32) 104 ∼ 110 (65 ∼ 68) —
3 Half throttle 22 ∼ 28 (14 ∼ 17) 57 ∼ 63 (35 ∼ 39) —
(Third)
Fully closed 13 ∼ 19 (8 ∼ 12) 23 ∼ 29 (14 ∼ 18) —
Fully opened 45 ∼ 51 (28 ∼ 32) 92 ∼ 98 (57 ∼ 61) —
2 Half throttle 22 ∼ 28 (14 ∼ 17) 92 ∼ 98 (57 ∼ 61) —
(Second)
Fully closed 13 ∼ 19 (8 ∼ 12) 92 ∼ 98 (57 ∼ 61) —
L
— 48 ∼ 54 (30 ∼ 34) — —
(First)
“Winter mode”
D range, winter mode ON → OFF 31 ∼ 37 km/h (19 ∼ 23 mph)
Lockup Speed Chart

Transfer gear ratio High: 1.000
Rear axle ratio 4.300
ECCC Apply ECCC Release

Mode 2nd 3rd 4th 2nd 3rd 4th
Km/h Km/h Km/h Km/h Km/h Km/h
D range Throttle (mph) (mph) (mph) (mph) (mph) (mph)
opening
i 6% 57 ∼ 63 42 ∼ 48 43 ∼ 49 52 ∼ 58 32 ∼ 38 41 ∼ 47
Normal
(35 ∼ 39) (26 ∼ 30) (27 ∼ 31) (32 ∼ 36) (20 ∼ 24) (25 ∼ 29)
57 ∼ 63 67 ∼ 73 57 ∼ 63 52 ∼ 58 32 ∼ 38 49 ∼ 55
Power
(35 ∼ 39) (42 ∼ 45) (35 ∼ 39) (32 ∼ 36) (20 ∼ 24) (30 ∼ 34)
Changing Transmission Fluid NOTE: To prevent fluid leaks, the overfill screw and oil
drain screws gasket must be replaced each time these
There is no need to change the transmission fluid unless screws are removed.
the transmission is used under one or more of the
following heavy duty conditions. NOTE: Check transmission fluid temperature with
A. Repeated short trips service scan tool.
B. Driving on rough roads 7. Reset “Oil Life Monitor” data by using Tech 2.
C. Driving on dusty roads Refer to Tech 2 OBD II Connection in Transmission
D. Towing a trailer Control System (4L30-E) section.
If the vehicle is used under these conditions, change the
fluid every 20,000 miles (32,000 km).
1. Place a large drain pan under the oil pan.
2. Remove the transmission oil drain screw (2) and drain
fluid.
3. Tighten drain screw (2).
4. Remove the transmission overfill screw (1) and fill
transmission through overfill screw opening, using
DEXRON–III ATF.
NOTE: Add transmission fluid until it flows out over the
overfill screw opening.
5. Let engine idle until a fluid temperature between 32°C
(90°F) and 57°C (135°F) is reached.
6. Add transmission fluid until it flows out over the overfill
screw opening, then close the overfill screw (1).
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Selector Lever
Inspection Removal
1. Make sure that when the selector lever is shifted from 1. Disconnect battery ground cable.
“P” to “L”, a “clicking” can be felt at each shift position. 2. Remove transfer control lever knob (4×4).
Make sure that the gear corresponds to that of the
3. Remove front console.
position plate indicator.
D Disconnect wiring harness connectors from front
2. Check to see if the selector lever can be shifted as
console.
shown in illustration.
4. Disconnect shift lock cable (1) from the selector lever
assembly side.
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5. Disconnect shift control rod (2) from the selector lever
assembly side.
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6. After adjustment, make sure that the selector lever

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operates normally, and that each selector position is
6. Disconnect wiring harness connectors from the properly indicated. (The red mark shows through the
selector lever assembly. window.)
7. Remove selector lever assembly. Adjustment of shift lock cable
1. Set ignition key in “LOCK” position and selector lever
Installation in “P” position.
To install, follow the removal steps in the reverse order, 2. Adjust cable screw cap on selector lever side to
noting the following points: provide a gap (slack for cable) of 1 – 2 mm between
Adjustment of select lever and control rod rod on steering lock side and stopper.
Adjust cap as follows:
1. Place the vehicle on a level surface.
a. Pull screw cap (1) in arrow direction to remove
NOTE: If the vehicle is not on level surface, the shift inner cable slack.
select cable set positions will vary with the movement of
b. With cable kept as (a), adjust gap between nut (2)
engine. To prevent possible misadjustment of the cable,
and bracket to 5 mm (0.2 in).
the vehicle must be placed on a level surface.
c. Lock inner cable by turning nut (3) while holding nut
2. Install the shift control rod (1) to the transmission (2) in place.
select lever (2), and then place the lever in the “N”
position. Torque : 3.7 N•m (33 lb in)
3. Set select lever in the “N” position. NOTE: Clean the cable threads, and do not apply oil to
4. Push select lever forward (“R” position side) and them.
secure it (using a rubber band (3), etc.) so that the pin
comes into contact with the wall of the detent plate.
5. Install the shift control rod (1) to the selector lever arm
(4).
NOTE: Do not apply oil to the threaded portions.
3. Check the shift lock operation:
a. Selector lever should not move out of “P” position
with ignition key in “Lock” position.
b. Selector lever can be moved out of “P” position with
ignition key in “ON” position only when brake pedal
is depressed.
c. Ignition key can be turned to “LOCK” position only
when selector lever is in “P” position (key can be
pulled out).
If (a) and (c) fail, readjust cable. If (b) fails, readjust
connector wiring and brake pedal switch.
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Mode Switch
1. Place selector lever in neutral. To install, follow the removal steps in the reverse order,
noting the following points;
1. Torque
3. Remove mode switch cover (1).
4. Disconnect selector lever (2) from the mode switch. Mode switch bolt: 13 N•m (113 lb in)
5. Disconnect transmission harness from the mode Selector lever nut: 23 N•m (17 lb ft)
switch connector (3). 2. Mode switch setting procedure
6. Remove bracket with mode switch connector from Perform either of the following adjustment
the transmission case. procedures:
7. Remove mode switch connector (3) from the bracket Procedure 1
(4).
a. Place selector lever in neutral.
8. Remove two mode switch bolts and nut then remove
mode switch (5). b. Remove selector lever from the mode switch.
c. Remove the mode switch cover.
d. Loosen the two 10 mm screws.
e. Rotate the mode switch until the slot in the mode
switch housing aligns with the selector shaft
bushing, and insert a 3/32 in. (2.4 mm) drill bit or
punch (1) into the slot.
f. Tighten the screws to 13 N·m (113 lb in).
g. After completing adjustment, snap the mode
switch cover into place.
h. Reinstall the selector lever.
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Procedure 2
a. Place selector lever in neutral.
b. Disconnect transmission harness connector from
mode switch connector.
c. Remove mode switch connector with bracket from
the transmission case.
d. Connect multimeter (resistance mode) to
terminals 1(E) and 4(H) on mode switch connector.
e. Loosen two mounting screws.
f. Rotate mode switch slightly in both directions to
determine the range (approx. 5 degrees) of
electrical contact.
g. Position mode switch in middle of contact range.
h. Tighten two mounting screws.
i. Remove multimeter and install mode switch
harness connector with bracket to the
transmission case.
j. Connect transmission harness connector to mode
switch connector.
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Transmission (With Transfer Case / Extension Assembly)

Transmission And Associated Parts
150RY00001
Legend (11) Left Catalytic Converter Assembly

(1) Transfer Control Lever Knob (4×4) (12) Seat Belt Tension Rod
(2) Front Console (13) Transmission Oil Cooler Pipe
(3) Selector Lever Assembly (14) Starter
(4) Transfer Control Lever (4×4) (15) Transmission Harness Connector
(5) Transfer Protector (4×4) (16) Front Crossmember
(6) Rear Propeller Shaft (17) Under Cover
(7) Front Propeller Shaft (4×4) (18) Torque Converter Bolt
(8) Harness Protector (19) Engine Transmission Bolt
(9) Rear Mount Nut (20) Transmission Assembly (With Transfer Case /
(10) Third Crossmember Extension Assembly)
Removal
NOTE: Before remove transmission and transfer
assembly from vehicle, change the tansfer mode to 2WD
using push button on dash panel.
1. Remove engine hood.
3. Remove transfer control lever knob (1) (4×4) and
disconnect wiring harness connectors, then remove
front console (2).
4. Remove selector lever assembly (3).
5. Remove transfer control lever (4) (4×4).
6. Remove transfer protector (5) (4×4).
7. Disconnect shift control rod from the selector lever
assembly side.
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16. Remove left catalytic converter assembly (11).

17. Loosen right catalytic converter nuts to exhaust
manifold.
NOTE: This will make the next steps easier.
18. Disconnect transmission oil cooler pipe (12) from A/T
side.
19. Remove oil pipe clamp from torque converter
housing bracket.
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8. Remove rear propeller shaft (6).

9. Remove front propeller shaft (7) (4×4).
10. Remove harness protector (8).
11. Support transfer case (4×4) or transmission (4×2)
with a jack and remove two rear mount nuts (9) from
the 3rd crossmember side.
12. Remove eight third crossmember bolts and third
crossmember (10).
13. Remove front exhaust silencer mounting nuts.
14. Remove left seat belt tension rod.
15. Disconnect two left side oxygen sensor connectors 253RY001
from the transmission harness. 20. Loosen oil pipe clamp bolt at the engine mount side.
21. Remove starter (14).
22. Disconnect fuel pipe clamp brackets from
transmission side.
23. Disconnect transmission harness connectors (15)
from transmission, transfer, and right catalytic
converter.
24. Remove front crossmember (16).
25. Remove under covers (3 pieces) (17) from
transmission case.
26. Remove flex plate torque converter fixing bolts (6
pieces) (18) by turning crankshaft.
27. Support the transmission with a transmission jack, Installation
and hoist engine with a chain block.
28. Remove engine transmission fixing bolts (19). 1. Slowly raise transmission jack until front of the
transmission is aligned with rear of the engine, then
29. Remove transmission assembly with transfer case install transmission assembly.
(4×4) / extension assembly (4×2) (20).
2. Tighten engine transmission bolts, to the specified
30. Remove transfer case / extension assembly from the torque.
transmission assembly if necessary.
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3. Support transfer case with a jack, and remove the

transmission jack.
4. Install flex plate torque converter bolts (6 pieces) by
turning crankshaft.
NOTE: Do not reuse the flex plate torque converter bolt.
240RY003
5. Install the under cover (3 pieces), and tighten the 7. Install the starter, and tighten the bolts to the specified
bolts to the specified torque. torque.
Torque: 8 N•m (69 lb in) Torque: 40 N•m (30 lb ft)
6. Install front crossmember. 8. Connect transmission harness connectors to
Torque: 78 N•m (58 lb ft) transmission, transfer, and right catalytic converter.
9. Connect fuel pipe brackets to transmission side.
For 4×4 (TOD)
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For 4×4
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For 4×2
141RY001
10. Install transmission oil cooler pipe to transmission. 15. Install left seat belt tension rod.
Torque: 44 N•m (33 lb ft) Torque: 39 N•m (29 lb ft)
11. Install oil pipe clamp to torque converter housing 16. Connect two left side oxygen sensor connectors to
bracket. the transmission harness.
12. Tighten oil pipe clamp bolt at engine mount side. 17. Install front exhaust silencer mounting nuts.
13. Install right catalytic converter, tighten to the specified 18. Install third crossmember, and tighten the bolts to the
torque. specified torque.
Torque: 67 N•m (49 lb ft) Torque: 76 N•m (56 lb ft)
14. Install left catalytic converter assembly, and tighten 19. Install rear mount nuts, and tighten the bolts to the
the bolts to the specified torque. specified torque.
Exh. pipe to exh. manifold 67 N•m (49 lb ft) Torque: 50 N•m (37 lb ft)
Exh. pipe flange bolt 43 N•m (32 lb ft) 20. Remove the jack from the transfer case.
21. Install harness protector.
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22. Install the front propeller shaft, and tighten the bolts to
the specified torque (4×4).
23. Install the rear propeller shaft, and tighten the bolts to
24. Connect the shift control rod to selector lever
assembly.
25. Install the transfer protectors, and tighten the bolts to
the specified torque (4×4).
26. Install the transfer control lever (4×4).
27. Install the selector lever assembly.
28. Connect the wiring harness connectors to front
console.
29. Install the front console.
30. Install the transfer control lever knob (4×4).
31. Connect the battery ground cable.
32. Install the engine hood.
Solenoid (Main Case Valve Body)

Removal 10. Remove shift solenoid A, shift solenoid B, band
control solenoid, and gaskets from main case valve
1. Raise the vehicle and support it on jack stands. body. Do not pull on wiring harness. Remove
2. Disconnect battery ground cable. solenoids by grasping the metal tip.
3. Remove transfer protector (4×4).
4. Drain fluid. Installation
5. Support transfer case with a jack and remove third 1. Install shift solenoid A, shift solenoid B, band control
crossmember. solenoid with new gaskets to main case valve body
6. Remove sixteen 10 mm screws, main case oil pan, respectively.
magnet, and gasket. 2. Carefully install spring pin with hammer to avoid
7. Remove three 13 mm screws, oil filter. damage to valve body, etc.
8. Disconnect wiring harness from band control
solenoid and shift solenoids. Pull only on connectors,
not on wiring harness.
9. Remove spring pin for shift solenoid A, shift solenoid
B, and band control solenoid respectively, using
suitable pliers taking care not to damage solenoids.
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3. Connect wiring harness to solenoids.

4. Install oil filter with a new gasket and the three 13 mm
screws. Tighten the screws to the specified torque.
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5. Install magnet, main case oil pan with new gasket,
sixteen 10 mm screws. Tighten the screws to the
specified torque.
Torque: 11 N•m (96 lb in)
6. Install third crossmember and rear mount nuts.
Tighten the nuts and bolts to the specified torque.
Third crossmember bolt: 76 N•m (56 lb ft)
Rear mount nut: 50 N•m (37 lb ft)
7. Install the transfer protector. Tighten the bolts to the
specified torque (4×4).
8. Fill transmission through the overfill screw hole of oil
pan, using ATF DEXRON–III. Refer to Changing
Transmission Fluid in this section.
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Solenoid (Adapter Case Valve Body)

1. Raise the vehicle and support it on jack stands. 1. Install force motor solenoid, retainer, and 11 mm bolt
2. Disconnect battery ground cable. to adapter case valve body. Tighten the bolt to the
specified torque.
3. Drain fluid.
4. Remove adapter case oil pan twelve fixing 10 mm Torque: 10 N•m (87 lb in)
screws, adapter case oil pan, and gasket. 2. Install converter clutch PWM solenoid with two O–
rings, bracket, and 11 mm bolt to adapter case valve
NOTE: Oil pan still contains transmission fluid. Place a
body. Tighten the bolt to the specified torque.
large drain container under the oil pan and drain the fluid
carefully. Torque : 10 N•m (87 lb in)
5. Disconnect wiring harness from force motor solenoid 3. Connect wiring harness assembly to solenoids.
and converter clutch PWM solenoid. Pull only on 4. Install adapter case oil pan, new gasket, and twelve
connectors, not on wiring harness. 10 mm screws. Tighten the screws to the specified
6. Remove 11 mm bolt, bracket and converter clutch torque.
PWM solenoid with two O–rings. Torque : 11 N•m (96 lb in)
5. Fill transmission through overfill screw hole oil pan,
using ATF DEXRON–III. Refer to Changing
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7. Remove 11 mm bolt, retainer, and force motor

solenoid.
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Valve Body Assembly (Main Case)

Removal 4. Install seven 13 mm screws, and tighten them to the
specified torque.
1. Raise the vehicle and support it on jack stands.
3. Remove transfer protector (4×4).
4. Drain fluid.
5. Support transfer case with a jack and remove third
crossmember.
6. Remove sixteen 10 mm screws, main case oil pan,
magnet and gasket.
7. Remove three 13 mm oil filter fixing screws, then
remove oil filter.
8. Remove two 13 mm manual detent fixing screws,
then remove roller and spring assembly.
9. Disconnect wiring harness from band control
solenoid and shift solenoids. Pull only on connectors,
not on wiring harness.
10. Remove four 13 mm servo cover fixing screws, then
remove servo cover and gasket.
11. Remove seven 13 mm valve body fixing screws.
12. Remove main case valve body with manual valve link
and transfer plate. Note the position of the link (long 243RS008
end into valve, short end into range selector lever). 5. Remove two guide pins from main case.
13. Remove transfer plate gasket from main case. 6. Install servo cover gasket, cover, and four 13 mm
screws. Tighten the screws to the specified torque.
14. Remove two check balls from main case.
Installation 7. Connect wiring harness to band control and shift
solenoids.
1. Install two check balls to main case. 8. Install roller and spring assembly to manual detent.
D Install two 13 mm screws, and tighten them to the
specified torque.
9. Install oil filter and three 13 mm screws. Tighten the
screws to the specified torque.
Torque : 20 N•m (15 lb ft)
10. Install oil pan gasket, magnet, oil pan and sixteen 10
mm screws. Tighten the screws to the specified
torque.
11. Install third crossmember and rear mount. Tighten the
bolts and nuts to the specified torque.
Torque
Third crossmember bolt: 76 N•m (56 lb ft)
Rear mount nut: 50 N•m (37 lb ft)
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12. Install transfer protector. Tighten the bolts to the
2. Inspect electrical 7 way connector and seal of main specified torque (4×4).
case. Replace if necessary. Torque: 37 N•m (27 lb ft)
3. Use two J–25025–B guide pin to install main case. 13. Fill transmission through overfill screw hole of oil pan,
D Install valve body assembly and manual valve link. using ATF DEXRON–III. Refer to Changing
NOTE: Valve must be extended as the short end of
manual valve link is connected to the range selector lever. 14. Connect battery ground cable.
Long end of link goes into valve.
Valve Body Assembly (Adapter Case)

1. Raise the vehicle and support it on jack stands. 1. Inspect electrical 4 way connector and seal of adapter
2. Disconnect battery ground cable. case. Replace if necessary.
3. Drain fluid. 2. Install gasket, transfer plate, and gasket.
4. Remove twelve 10 mm adapter case oil pan fixing 3. Install adapter case valve body and seven 13 mm
screws, adapter case oil pan, and gasket. screws. Tighten the screws to the specified torque.
NOTE: Oil pan still contains transmission fluid. Place a Torque: 20 N•m (15 lb ft)
large drain container under the oil pan. 4. Connect wiring harness assembly to converter clutch
Drain the fluid carefully. solenoid and force motor.
5. Disconnect wiring harness from force motor solenoid 5. Install oil pan gasket, oil pan, and twelve 10 mm
and converter clutch solenoid. Pull only on screws. Tighten the screws to the specified torque.
connectors, not on wiring harness. Torque: 11 N•m (96 lb in)
6. Remove seven 13 mm screws from adapter case 6. Fill transmission through the overfill screw hole of oil
valve body assembly, then remove transfer plate, two pan, using ATF DEXRON–III. Refer to Changing
gaskets, and adapter case valve body. Transmission Fluid in this section.
Powertrain Control Module (PCM)

1. Disconnect battery ground cable. 1. Install PCM to bracket.
2. Disconnect PCM wiring harness connectors from 2. Connect PCM wiring harness connectors to PCM.
PCM. 3. Connect battery ground cable.
3. Remove PCM from bracket.
826RY001
Speed Sensor (Extension Housing)

1. Disconnect battery ground cable. 1. Inspect the speed sensor O–ring, and replace it if
2. Remove front console. necessary.
3. Remove selector lever assembly. 2. Install speed sensor assembly and 10 mm screw.
4. Disconnect speed sensor harness connector from Torque: 9 N•m (78 lb in)
speed sensor. 3. Connect speed sensor harness connector to speed
5. Remove one 10 mm screw and speed sensor with sensor.
O–ring. 4. Install selector lever assembly.
D Adjust shift lock cable. Refer to Selector Lever in
this section.
5. Install front console.
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Transmission Oil Temperature Sensor (Main Case)

Removal
1. Raise the vehicle and support it on jack stands.
3. Drain fluid.
4. Remove sixteen 10 mm main case oil pan fixing
screws, main case oil pan, and gasket.
5. Disconnect wiring harness from shift solenoids, band
apply solenoid, and 7 way connector of main case.
Pull only on connectors, not on wiring harness.
6. Remove wiring harness assembly with transmission
oil temperature sensor.
244RY001
Installation
1. Install wiring harness assembly with transmission oil
temperature sensor to band apply solenoid, shift
solenoids, and 7 way connector of main case.
2. Install oil pan gasket, oil pan, and sixteen 10 mm 3. Fill transmission through the overfill screw hole of oil
fixing screws. Tighten the screws to the specified pan, using ATF DEXRON–III.
torque. Refer to Changing Transmission Fluid in this section.
Torque: 11 N•m (96 lb in) 4. Connect battery ground cable.
Front Oil Seal (Converter Housing)

1. Remove transmission assembly with transfer case 1. Apply clean ATF to the new oil seal ring lip.
from the vehicle. Refer to Transmission (With D Install oil seal ring to converter housing. Tighten the
Transfer Case / Extension Assembly) in this section. screws to the specified torque.
2. Remove torque converter from converter housing. Torque: 3 N•m (26 lb in)
3. Remove three screws and oil seal ring from converter
2. Install torque converter to converter housing.
housing.
3. Install transmission assembly with transfer case
(4×4) / extension assembly (4×2) to the vehicle. Refer
to Transmission (With Transfer Case / Extension
Assembly) in this section.
241RW008
Rear Oil Seal (Extension Housing)

Removal
1. Remove transfer case assembly (4×4) or extension
assembly (4×2) from the vehicle. Refer to Transfer
Case in Drive Line/Axle section.
2. Remove rear oil seal from transmission extension
housing.
241RW005
Installation 2. Install the transfer case assembly (4×4) or extension

assembly (4×2) to the vehicle. Refer to Transfer Case
1. Use J–36797 extension housing oil seal installer, and in Drive Line/Axle section.
install the rear oil seal to the transmission extension
housing.
Transmission (4L30–E)
Disassembly 2. Remove O–ring (2) from turbine shaft.
3. Remove two 10mm mode switch screws, selector
NOTE: During the disassembly and reassembly, perform lever nut, cover, and mode switch (3).
the following:
4. Remove twelve 10mm adapter case oil pan (4) fixing
D Wash each part thoroughly, and blow air through each screws, adapter oil pan, and gasket.
oil passage and groove to eliminate blockage. 5. Disconnect electrical wiring connections (5) from
D Seal rings, roll pins, and gaskets should be replaced. solenoids and 4 way connector of adapter case. Pull
D When assembling the components, apply on connectors only, not on wiring harness.
DEXRON–III Automatic Transmission Fluid (ATF) 6. Remove seven 13mm adapter case valve body (6)
to each seal, rotating part, and sliding part. fixing screws, adapter case valve body assembly,
D Do not dip part facings, such as clutch or brake drive transfer plate, and two gaskets.
plates, in cleaner when washing it. D Remove wiring harness and 4 way connector.
Also, always coat parts with new ATF two or three 7. Remove sixteen 10mm main case oil pan (7) fixing
times after cleaning with solvent. screws, main oil pan, magnet, and gasket.
1. Remove torque converter (1). 8. Remove three 13mm oil filter (8) fixing screws and oil
D Drain fluid from torque converter. filter.
D Attach J–8763–02 holding fixture to the 9. Remove two 13mm manual detent (9) fixing screws,
transmission and set it on J–3289–20 holding roller and spring, and manual detent.
fixture base. 10. Disconnect wiring harness assembly (10) from band
apply solenoid, shift solenoids, and main case 7 way
NOTE: Do not overtighten the tool, as case damage may connector.
result. Pull on connectors only, not on wiring harness.
11. Remove four 13mm servo cover (11) fixing screws,
servo cover, and gasket.
12. Remove seven 13mm valve body screws and ground
wire from main case.
D Remove wiring harness assembly (5) from the
adapter case side.
D Remove main valve body assembly (12) with
manual valve link and transfer plate. Note the
position of the link (long end into valve, short end
into range selector lever).
D Remove 7 way connector.
D Remove gasket transfer plate from main case.
420RW021
13. Remove two check balls (13) from main case.
240RY001
14. Turn transmission to vertical position to drain fluid.

Return back to horizontal position when drained.
D Install J–23075 servo piston spring compressor
with offset to the rear of case.
D Compress servo piston assembly.
D Remove servo piston retaining ring (14).
D Slowly release servo piston assembly (15).
D Remove tool.
15. Remove servo piston assembly (15), return spring 19. Remove speed wheel (21).
(16), and servo apply rod (17). 20. Remove wheel parking lock (with seal ring) (22).
242RS002
241RS002
16. Rotate transmission to horizontal position, pan side 21. Rotate transmission to vertical position, converter
down. housing up.
D Remove one 10mm screw, and speed sensor (18) D Loosen the converter housing and oil pump
with “O” ring. assembly fixing screws, but do not remove the five
17. Remove seven 8mm extension housing hexagon 13 mm inner screws if oil pump disassembly is
socket head screws, extension housing assembly required.
(19), and gasket. D Remove seven outer screws.
18. Remove retaining ring (20).
D Remove converter housing and oil pump assembly
NOTE: Use extra long, needle- nose pliers. (23).
22. Remove gasket (24).
23. Remove selective thrust washer (25). 28. Remove thrust washer (31).
241RW004 252RS001
24. Remove fourth clutch retainer (26). 29. Remove adapter case and center support assembly
25. Grasp turbine shaft and lift out the overrun clutch (with fourth clutch piston) (32).
housing assembly (27) and fourth clutch plates (28). 30. Remove seal ring (33).
26. Remove thrust bearing assembly (29). 31. Remove selective thrust washer (34) and two O–ring
27. Remove overdrive internal gear (30). seals (35) from main case.
32. Use J–23327 and J–23327–90 compressor to
compress the fourth clutch spring retainer and
springs (37).
D Release snap ring (36) from groove.
D Remove clutch compressor and snap ring (36).
33. Remove retainer and spring assembly (37).
34. Insert two converter housing/main case screws to
hold adapter case while pulling out fourth clutch
piston (38).
D Remove fourth clutch piston assembly (38) from the
adapter case.
D Remove converter housing/main case screws.
35. Grasp intermediate shaft, twist and pull out the
second and third clutch drum assemblies with reverse
clutch plates while holding onto output shaft (39).
36. Separate second (40) and third clutch (41) NOTE: Insert wire in the center of the spring pin to
assemblies. prevent it from collapsing during removal. Be aware of pin
37. Remove thrust washer (42). height. Protect machined face of main case.
38. Remove reverse clutch plates (43 and 44) and 48. Remove parking lock and range selector lever 17 mm
reverse clutch pressure plate (45). nut (57).
39. Remove bearing (46) and washer (47). 49. Remove parking lock and range selector lever (56),
40. Remove planetary carrier assembly (48). and actuator assembly.
41. Remove thrust bearing (49). 50. Remove selector shaft (58).
42. Remove reaction sun gear (50) NOTE: Inspect the shaft for burrs before removing to
43. Remove needle bearing (51). prevent damaging seal. If necessary, remove burrs by
lightly sanding with an oilstone.
44. Remove brake drum (52).
45. Remove brake band (53).
46. Remove thrust bearing (54).
249RS004
Reassembly
1. Inspect selector shaft seal, and replace it if
necessary.
NOTE: Use a seal installer when replacing the seal.
D Install selector shaft.
NOTE: Spring pin groove must be positioned inside the
case.
2. Install spring pin. Be sure the selector shaft can move
freely. Do not push the pin flush with the case surface.
242RS003
Leave enough height for removal.
47. Rotate case to horizontal position, valve body side
facing up. 3. Install actuator assembly (1).
D Remove spring pin (55), using cutting pliers, then 4. Install parking lock and range selector lever (2) and
remove parking lock and selector lever assembly new 17 mm nut. Tighten the nut to the specified
(56). torque.
11. Install the thrust bearing (9) on the output shaft.
NOTE: Use petroleum jelly to hold the thrust bearing in
place.
12. Align planetary pinions. Each pinion is marked with
double points to indicate the master tooth space and
exactly opposite with a single point to indicate the
master tooth. The markings on the planetary carrier
consist of double lines which are to be lined up with
the double points on two opposite pinions; the single
lines are to be lined up with the single points on the
other two pinions.
D After all four pinions are lined up, slide on the third
clutch assembly. Rotate third clutch and check
mark alignment. Considering that the ring gear
tooth between the double points of one planetary
pinion is tooth number 1, count the teeth to check
that the single points on the two adjacent pinions
are between teeth 23 and 24 of the ring gear, and
249RS005
that the ring gear tooth between the double points of
5. Rotate main case to vertical position, extension end the opposite pinion is tooth number 46. If the ring
facing down. gear and pinions are not lined up, remove, and
realign them.
D Install brake band assembly (3).
13. Install planetary carrier (8) with third clutch (12).
NOTE: Be sure to align servo pin area with the servo hole.
NOTE: Do not force. When properly aligned, the parts will
6. Install thrust bearing (4). fit together easily.
NOTE: The case bushing acts as a guide for the thrust
bearing.
7. Install brake drum (5).
8. Install reaction sun gear (6).
9. Install needle bearing (7).
10. Inspect planetary carrier assembly (8) for wear and
damage. If necessary replace it.
D Measure pinion end play clearance with a feeler
gauge.
Clearance: 0.13mm–0.89mm (0.005 in–0.035 in)
If clearance is outside specified value, replace the
planetary carrier assembly.
248RS002
14. Remove the third clutch (12).

15. Install bearing (11) and washer (10).
248RS001
NOTE: Use petroleum jelly to hold the washer and 18. Install second and third clutch assemblies into the
bearing in place. main case. Twist output shaft and clutch assemblies
to ensure proper fit.
247RS001
19. Install pressure plate (15) with lip side up, tang facing
valve body face.
20. Install reverse clutch plates. Start with a steel plate
(17) and alternate with a lined plate (16).
21. Install waved clutch plate (18) with center tang facing
valve body side.
242RW002
16. Carefully align the second clutch plate inner tangs.

D Install thrust washer, tangs pointing downward, and
locating tang positioned in slot on second clutch
hub.
NOTE: Use petroleum jelly to hold thrust washer in place.
17. Install third clutch and intermediate shaft assembly
(13) into the second clutch drum (14).
247RS002
22. Second clutch end play measurement
1. Install the J–23085–A Selective washer gauging
tool (with spacer ring) on the case flange and
against the intermediate shaft.
2. Position the inner shaft of the gauging tool against
the thrust surface of the second clutch hub.
3. Tighten thumb screw. Remove the tool.
4. Fit the spacer ring on the inner shaft of the tool.
5. Measure the gap, and select the appropriate
washer as shown in the chart.
Selective Thrust Washer

Gap: mm(in) Color
1.53 – 1.63 (0.060 – 0.064) Yellow
1.72 – 1.82 (0.068 – 0.072) Red
1.91 – 2.01 (0.075 – 0.079) Black
247RS004
2.10 – 2.20 (0.083 – 0.087) Natural 23. Inspect fourth clutch piston seals and replace if
necessary.
2.29 – 2.39 (0.090 – 0.094) Green
D Lubricate J–38554 fourth clutch piston fitter and
2.48 – 2.58 (0.098 – 0.102) Blue install it on fourth clutch piston (19).
FOLLOWING THE PROCEDURE SHOULD D Install fourth clutch piston (19) in adapter case (20).
RESULT IN FINAL END–PLAY FROM 0.36 mm TO
0.79 mm (0.014 in TO 0.031 in) D Remove fitter.
252RS003
247RS003
24. Install retainer and spring assembly (22) into fourth 26. Install selective washer using petroleum jelly.
clutch piston (21). 27. Install two O–ring seals (24) in main case and adapter
25. Install snap ring (23) in adapter case. case/main case seal ring (25).
D Install J–23327 and J–23327–90 fourth clutch 28. Install J–38588 guide pins.
spring compressor. D Install adapter case and center support assembly to
D Seat snap ring in groove. main case.
D Remove compressor.
252RW002
242RS004
29. Install thrust washer (26) into adapter case, with

tangs pointing downwards.
30. Preassemble overdrive internal gear (27) and thrust
bearing assembly (28) onto the turbine shaft and
overrun clutch assembly.
NOTE: Install bearing assembly, black side up. Use
petroleum jelly to keep assembly in place.
31. Install overdrive carrier (30) and internal gear
assembly into adapter case.
252RS004 32. Install fourth clutch plates (29) in the following order:
Steel, Lined, Steel, Steel, Lined, Steel. Steel plates
go in with short tang facing towards valve body
surface.
33. Install fourth clutch retainer (31) with the notch facing
up and positioned towards valve body surface.
252RS005
252RW004
34. Overdrive clutch end play measurement

1. Install the J–23085–A selective washer gauging
tool on the adapter case flange and against the
input shaft.
2. Position the inner shaft of the tool against the
thrust surface of the overrun clutch housing.
3. Tighten thumb screw. Remove the tool.
4. Measure gap. Select appropriate size washer as
shown in the chart.
5. Set selective thrust washer aside.
Selective Thrust Washer

Gap: mm(in) Color
1.53 – 1.63 (0.060 – 0.064) Yellow
1.72 – 1.82 (0.068 – 0.072) Red 252RS006
35. Install selective washer (32).

1.91 – 2.01 (0.075 – 0.079) Black
NOTE: Use petroleum jelly to hold selective washer in
2.10 – 2.20 (0.083 – 0.087) Natural place.
2.29 – 2.39 (0.090 – 0.094) Green 36. Install gasket (33).
2.48 – 2.58 (0.098 – 0.102) Blue 37. Install converter housing and oil pump assembly (34)
to adapter case.
FOLLOWING THE PROCEDURE SHOULD
RESULT IN FINAL END–PLAY FROM 0.1 mm TO D Fit and tighten seven outer 13 mm screws.
0.8 mm (0.004 in TO 0.03 in) Torque: 39 N•m (29 lb ft)
D Ensure free rotation of pump using J–23082–01 oil 6. Remove axial play checking tool and puller.
pump rotation tool.
NOTE: If end play is not correct, repeat selective washer
selection.
252RW001
39. Inspect extension housing oil seal and replace if

necessary, using J–36797 extension housing oil seal
installer.
D Rotate transmission to horizontal position, with
valve body side down.
D Inspect parking wheel seal ring. Replace if
necessary.
241RW010
D Install wheel parking lock assembly (35).
38. Overdrive clutch end play measurement 40. Install speed wheel (36) and snap ring (37).
1. Fit J–25022 and J–24773–1 turbine shaft puller NOTE: Use extra long, needle-nose pliers.
on turbine shaft.
41. Install gasket onto extension assembly with a thin
2. Position axial play checking tool on converter coating of oil.
housing mating face.
D Install extension housing assembly (38), and align
3. Pull turbine shaft upwards with puller until first parking pawl shaft.
resistance is met. (due to weight of overdrive
D Install actuator assembly into extension assembly.
assembly).
D Install seven 8 mm hexagon socket head screws.
4. Maintain shaft in this position and set indicator to
zero. Torque: 32 N•m (24 lb ft)
5. Pull turbine shaft further upwards with puller. 42. Inspect speed sensor O–ring. Replace if necessary.
Read end play shown on indicator. D Install speed sensor assembly (39) and 10 mm
End play: 0.1mm – 0.8mm (0.004 in – 0.031in) screw.
43. Main case end play measurement
1. Attach axial play checking tool on the extension
housing and set indicator to zero on output shaft.
2. Manually push output shaft upwards.
End play: 0.36mm – 0.80mm (0.014 in – 0.031in)
3. Remove axial play checking tool.
4. If end play is not correct, repeat selective washer
selection.
241RS005
241RW009
44. Inspect servo piston seal ring. Replace if necessary.
D Ensure brake band is correctly positioned. Rotate
output shaft if necessary.
D Install J–38428 servo piston fitter in servo bore.
D Install apply rod (40), round end toward band, return
spring (41) and piston assembly (42).
45. Install the J–23075 servo spring compressor with
offset to rear of case.
D Compress servo piston seal ring, using fitter while
tightening the tool screw.
D Install servo piston retaining ring (43).
D Remove tool.
D Adjust the brake band by tightening the servo
adjusting screw to 4.5 N·m torque. Be certain the
lock nut is loose, then back–off the screw five turns
exactly. Hold piston sleeve with wrench and tighten
lock nut to 18.5 N·m torque. Be certain the adjusting
241RS004 screw does not turn.
NOTE: Valve must be extended as the short end of
manual valve link is connected to the range selector lever.
Long end of link goes into valve.
D Install seven 13 mm screws.
D Remove two guide pins.
49. Install servo cover gasket, cover (46) and four 13 mm
screws.
50. Connect wiring harness (47) to band control, shift
solenoids, and main case 7 way connector.
51. Install manual detent roller and spring assembly (48)
with clip.
D Install two 13 mm screws.
52. Install oil filter (49), and three 13 mm screws.
53. Install oil pan gasket, magnet, main oil pan (50), and
sixteen 10 mm screws.
54. Inspect adapter case electrical connector and seal.
Replace if necessary.
D Install electrical five pin connector and harness
assembly (52) in bottom of adapter case.
55. Install gasket, transfer plate, and gasket.
242RW004
D Install adapter case valve body (51) and seven 13
46. Install two check balls (44). mm screws.
56. Connect wiring harness harness assembly (52) to
converter clutch PWM solenoid, force motor, and 4
way connector.
57. Install oil pan gasket, adapter case oil pan (53), and
twelve 10 mm screws.
D Rotate transmission, with bottom pan facing down.
58. Install mode switch (54), two 10 mm screws, selector
lever nut, and cover.
10 mm screw
Nut
D Adjust using setting tool, refer to Mode Switch in
this section.
244RW002
47. Inspect main case electrical connector and seal, 59. Install O–ring (55) on turbine shaft.
replace if necessary. 60. Install torque converter (56).
D Install electrical 7 way connector/main case and The converter assembly must be replaced under any
wiring harness. of the following conditions:
48. Install two J–25025–B guide pins into main case. a. Evidence of damage to the pump assembly.
D Install main case valve body complete assembly b. Metal particles are found after flushing the cooler
(45) and manual valve link. lines.
c. External leaks in hub weld area.
d. Converter pilot broken, damaged, or poor fit into
crankshaft.
e. Converter hub scored or damaged. 61. Fill transmission through the overfill screw hole of oil
f. Internal failure in stator. pan, using ATF DEXRON–III. Refer to Changing
g. Contamination from engine coolant.
h. Excess end play.
D Rotate transmission, bell housing up. Spin
converter to insure proper fit.
240RY002
Converter Housing And Oil Pump Assembly

Disassembled View
241RY001
Legend (4) Wear Plate

(1) Converter Housing (5) Oil Pump Assembly
(2) Outer Seal Ring (6) Oil Seal Ring
(3) Gasket
Disassembly D Tighten five inner 13mm bolts in an alternating

pattern.
1. Remove oil pump assembly from converter housing.
2. Remove outer seal ring.
3. Remove gasket.
4. Remove wear plate.
5. Remove oil seal ring.

Visual Check:
If any damage, deformation, or local wear is found in a
converter housing, outer seal ring, wear plate, or oil seal
ring, replace it.
Reassembly
1. Install wear plate onto oil pump assembly.
2. Install converter housing onto complete oil pump
assembly. Align with two short J–38588 guide pins on
outer bolt holes.
D Loosely install five 13mm bolts. 241RW002
D Center converter housing using J–38557 centering 3. Install oil seal ring (3 screws).
tool. Torque: 3 N•m (26 lb in)
4. Install gasket.
5. Install outer seal ring.
Oil Pump
Disassembled View
241RY002
Legend (15) Enable Valve Spring Guide

(1) Oil Pump Drive Gear (16) Enable Valve Spring
(2) Oil Pump Driven Gear (17) Enable Valve
(3) Pin (18) Snap Ring
(4) Plug (19) Spring Seat
(5) Seal Ring (20) Throttle Signal Accumulator Spring
(6) Torque Converter Clutch Control Valve (21) Throttle Signal Accumulator Piston
(7) Converter Clutch Control Valve Spring (22) Sleeve Pin
(8) Pin (23) Boost Valve Sleeve
(9) Converter Clutch Regulator Sleeve (24) Boost Valve
(10) Converter Clutch Regulator Spring (25) Spring Seat
(11) Converter Clutch Regulator Valve (26) Pressure Regulator Valve Spring
(12) Isolator Spring (27) Spring Seat
(13) Isolator Valve (28) Pressure Regulator Valve
(14) Pin (29) Oil Pump Assembly
Disassembly 5. Remove torque converter regulator sleeve (9),

converter clutch regulator spring (10), converter
1. Remove oil pump drive gear (1) and driven gear (2). clutch regulator valve (11), isolator spring (12) and
2. Remove pin (3) from oil pump assembly (29). isolator valve (13).
3. Remove plug (4) and seal ring (5), torque converter 6. Remove pin (14) from oil pump assembly (29).
clutch control valve (6) and spring (7). 7. Remove enable valve spring (16), spring guide (15)
4. Remove pin (8) from oil pump assembly (29). and enable valve (17).
8. Remove snap ring (18) from oil pump assembly (29).
9. Remove spring seat (19), spring (20) and throttle
signal accumulator piston (21).
10. Remove sleeve pin (22) from oil pump assembly (29).
11. Remove boost valve sleeve (23), boost valve (24),
spring seat (25), valve spring (26), spring seat (27),
and pressure regulator valve (28).

Visual Check:
If any damage, deformation or wear is found, replace the
damaged part.
Reassembly
1. Lubricate and preinstall pressure regulator spring
seat (27) on valve (28), with the flat side against
shoulder.
2. Install pressure regulator valve (28) and spring seat
(27) assembly, valve spring (26), and spring seat (25)
with the flat side away from spring to oil pump
assembly (29).
3. Assemble boost valve (24) into sleeve (23).
4. Install boost valve and sleeve assembly, and sleeve
pin (22) to oil pump assembly (29).
5. Install throttle signal accumulator piston (21), spring
(20), and spring seat (19), with the flat side away from
the spring, and snap ring (18) to oil pump assembly
(29).
6. Install enable valve (17), spring guide (15), enable
valve spring (16) and retainer pin (14) to oil pump
assembly (29).
7. Assemble torque converter regulator spring (10) and
torque converter regulator valve (11) into sleeve (9).
8. Install isolator valve (13), isolator valve spring (12)
and the torque converter regulator sleeve and valve
assembly into the oil pump assembly (29).
9. Install torque converter clutch control valve spring (7),
torque converter clutch control valve (6), plug (4) and
seal ring (5), and retainer pin (3) to oil pump assembly
(29).
10. Install oil pump driven gear (2) and drive gear (1).
Main Case Valve Body

Disassembled View
244RS010
Legend (15) Spring

(1) Gaskets and Transfer Plate (16) Spring Pin
(2) Manual Valve (17) Plug
(3) Band Control Solenoid (18) Spring
(4) Pin (19) Low Pressure Control Valve
(5) Waved Washer (20) Spring Pin
(6) Spring Pin (21) Plug
(7) Solenoid A (22) Band Control Screen Assembly
(8) Retainer (23) Spring Pin
(9) 1–2/3–4 Shift Valve (24) Plug
(10) Spring (25) 1–2 Accumulator Valve
(11) Spring Pin (26) 1–2 Accumulator Control Valve
(12) Solenoid B (27) Check Ball
(13) Retainer (28) Main Case Valve Body
(14) 2–3 Shift Valve
Disassembly 5. Remove spring pin (6) with a 3 mm dia punch.

6. Remove solenoid A (7) by grasping the metal tip. Do
1. Remove two 11mm bolts from valve body (28), then not grasp the connector housing.
remove gaskets and transfer plate (1).
7. Remove retainer (8), 1–2/3–4 shift valve (9), and
2. Remove manual valve (2). spring (10).
3. Push in band control solenoid (3) to compress waved 8. Remove spring pin (11) with a 3 mm dia punch.
washer (5), and remove pin (4).
9. Remove solenoid B (12) by grasping the metal tip. Do
4. Remove band control solenoid (3) and waved washer not grasp the connector housing.
(5).
10. Remove retainer (13), 2–3 shift valve (14), and spring 9. Install gasket (valve body/transfer plate) and transfer
(15). plate using two J–3387–2 guide pins.
11. Remove spring pin (16), plug (17), spring (18), and D Install two 11mm bolts.
low pressure control valve (19). Torque: 13 N•m (113 lb in)
12. Remove spring pin (20), plug (21), and band control
screen assembly (22).
13. Remove spring pin (23), plug (24), 1–2 accumulator
valve (25), and 1–2 accumulator control valve (26).
14. Remove check ball (27) from valve body (28).

Inspect for the following, and replace any damaged or
worn parts:
1. Damage or wear to each valve.
2. Damage in oil passeges.
3. Cracks or damage to valve body.
4. Valve operations.
5. Spring fatigue.
Reassembly
1. Install 1–2 accumulator control valve (26), 1–2 244RS004
accumulator valve (25), plug (24), and spring pin (23). D Install gasket (transfer plate/main case).
2. Install band control screen assembly (22), plug (21),

and spring pin (20).
3. Install low pressure control valve (19), spring (18),
plug (17), and spring pin (16).
4. Install spring (15), 2–3 shift valve (14), retainer (13),
solenoid B (12), and spring pin (11).
5. Install spring (10), 1–2/3–4 shift valve (9), retainer (8),
solenoid A (7), and spring pin (6).
6. Install waved washer (5), band control solenoid (3),
and pin (4).
7. Install manual valve (2).
8. Install check ball (27) to valve body (28).
Adapter Case Valve Body

Disassembled View
243RY001
Legend (9) Spring

(1) Bracket (10) Retaining Ring
(2) Converter Clutch PWM Solenoid (11) Feed Limit Valve
(3) Retainer (12) Plug Retainer
(4) Force Motor Solenoid (13) O–Ring
(5) Retainer (14) Plug
(6) Plug (15) Force Motor Screen Assembly
(7) 3/4 Accumulator Valve (16) Adapter Case Valve Body
(8) 3/4 Accumulator Control Valve
Disassembly Inspection And Repair

1. Remove 11mm bolt from valve body. Inspect for the following, and replace any damaged or
worn parts:
D Remove bracket (1) and converter clutch PWM
solenoid (2). 1. Damage or wear to each valve.
2. Remove 11mm bolt and retainer (3) from valve body. 2. Damage in oil passeges.
D Remove force motor solenoid (4). 3. Cracks or damage to valve body.
3. Remove retainer (5), plug (6), 3/4 accumulator valve 4. Valve operations.
(7), and 3/4 accumulator control valve (8). 5. Spring fatigue.
4. Remove spring (9), retaining ring (10), and feed limit
valve (11). Reassembly
5. Remove plug retainer (12), O–ring (13), plug (14),
and force motor screen assembly (15). 1. Install force motor screen assembly (15), plug (14),
O–ring (13), and plug retainer (12).
D Use 5 mm bolt to pull plug.
2. Install feed limit valve (11), retaining ring (10), and
spring (9).
3. Install 3/4 accumulator control valve (8), 3/4
accumulator valve (7), plug (6), and retainer (5).
4. Install force motor solenoid (4).
D Place solenoid terminals pointing towards mating
face.
D Install retainer (3) and bolt.
5. Install converter clutch PWM solenoid (2) with two
O–rings (2) and bracket (1) to valve body.
D Install bolt.
Third Clutch And Sprag Unit

Disassembled View
248RW001
Legend (5) Thrust Washer

(1) Retaining Ring (6) Clutch Plates
(2) Input Sun Gear and Sprag Unit Assembly (7) Third Clutch Spring Cushion Plate
(3) Retaining Washer (8) Third Clutch Drum Assembly
(4) Bearing
Disassembly
1. Place the third clutch drum and intermediate shaft
assembly upright, using the overdrive internal gear as
a support.
2. Locate the ends of the retaining ring. Depress one
end of the ring using a small screwdriver instead of
the depressor handle provided with the tool
J-38450-A. Slide one blade down between the third
clutch drum and the retaining ring.
3. Remove a screwdriver and repeat this step for the
other end of retaining ring.
4. Install the remaining four blades approximately (five)
notches apart using a screwdriver to depress the
retaining ring.
5. Pull up on input sun gear and sprag unit assembly (1
and 2) to release the retaining ring from third clutch
drum assembly (8).
6. Remove the tool blades. 248RX001
7. Remove retaining washer (3), bearing (4), thrust

washer (5), and clutch plates (6 and 7) from the third
clutch drum assembly (8).

Visual Check:
damaged part.
Reassembly
1. Place third clutch drum and intermediate shaft
assembly upright, using the overdrive internal gear as
a support.
2. Install third clutch spring cushion plate (7), bevel face
down.
3. Install third clutch plates (6) into third clutch drum
assembly (8). Start with the steel clutch plate and
alternate with lined plates.
4. Install thrust washer (5), bearing (4), and retaining
washer (3).
5. Fully engage the hub splines of the input sun gear and
sprag unit assembly (2) into the third clutch inner
tangs.
D Simultaneously rotate the outer sprag race to
engage into the third clutch drum assembly (8).
6. Place J-38450-A blades between the retaining ring
and the third clutch drum apporximately (five)
notches apart, and one blade at each end of the
retaining ring (1). Push down on sprag assembly until
the assembly is seated into the third clutch drum
assembly (8).
7. Remove the tool blades and engage retaining ring
into groove of third clutch drum.
248RX002
Third Clutch
Disassembled View
248RS006
Legend (3) Springs

(1) Retaining Ring (4) Piston Assembly
(2) Spring Seat (5) Third Clutch Drum
Disassemble 2. Release the spring seat (2).
1. Compress spring seat using the J–23075 spring NOTE: Do not let the spring seat catch in the ring groove.
compressor and J–23075–12 adapter tool. D Remove spring seat (2) and springs (3).
NOTE: Do not over–stress the springs and seat. This will 3. Remove piston assembly (4) from third clutch drum
cause damage to the spring seat. (5).
D Remove the tool.
D Remove retaining ring (1). Inspection And Repair
Visual check:
damaged part.
Operation check:
Shake the piston and listen for check ball movement
indicates proper check ball operation. Replace the piston
if the check ball is missing or falls out.
Reassembly
1. The lip of the piston seal must point toward the front of
the transmission. Lubricate the seal lip with
transmission fluid.
D Install piston assembly (4) into the third clutch drum
(5). Use the J–23084 third clutch piston installer to
protect the outer seal during installation.
D Remove the seal installer.
248RS007
248RS008
2. Install twelve springs (3) and spring seat (2).

3. Place retaining ring (1) onto spring seat.
D Compress the piston springs, using the J–23075
piston spring compressor and J–23075–12
adapter.
CAUTION: Do not over stress the springs and seat.
Do not let the spring seat catch in the ring groove.
This may cause damage to the spring seat.
D Install spring seat retaining ring (1).
D Remove the piston spring compressor and adapter.
Sprag Unit
Disassembled View
248RS009
Legend (4) Sprag Assembly

(1) Retaining Ring (5) Ring
(2) Sprag Outer Race (6) Third Clutch Hub and Sun Gear Assembly
(3) Ring
Disassembly NOTE: Check correct rotation by holding the sun gear in

your left hand and turning the outer race. The outer sprag
1. Remove the sprag outer race, retaining ring, and race should turn freely towards you and should lock
sprag assembly from the third clutch hub and sun turning away from you.
gear assembly.
2. Remove the rings and sprag assembly from the sprag
outer race.

Visual Check:
damaged part.
Reassembly
NOTE: Flared shoulder of the sprag cage faces the sun
gear. This procedure must be followed exactly to be sure
that the sprag assembly is installed properly.
1. Install rings and sprag assembly onto the third clutch
hub and sun gear.
2. Install sprag outer race and retaining ring assembly
over the sprag cage assembly. 248RS010
D Place third clutch hub and sun gear assembly on a

flat surface, sun gear facing up. Place sprag outer
race and sprag assembly over the sun gear
assembly, push down and turn the input sun
counterclockwise at the same time.
Second Clutch
Disassembled View
247RW001
Legend (6) Waved Washer

(1) Retaining Ring (7) Retaining Ring
(2) Ring Gear (8) Spring Seat
(3) Retaining Ring (9) Springs
(4) Spacer (10) Piston Assembly
(5) Clutch Plates (11) Second Clutch Drum
Disassembly
1. Remove retaining ring (1) from second clutch drum
(11).
2. Remove ring gear (2), retaining ring (3), and spacer
(4).
3. Remove clutch plates (5) and waved washer (6).
4. Remove retaining ring (7) using J–23327 compressor
to compress the spring seat (8).
5. Remove spring seat (8), springs (9) and piston
assembly (10) from second clutch drum (11).
247RS006
Inspection And Repair 2. Install twenty–two piston springs (9) and spring seat
(8) on the second clutch piston (10). Place retaining
Visual Check: ring (7) onto spring seat.
If any damage, deformation or wear is found, replace the D Use the J–23327 compressor to compress the
damaged part. piston springs.
NOTE: Do not let spring seat catch in ring groove.
Operation Check:
D Remove the compressor.
Shake the piston and listen for check ball movement.
Movement indicates proper check ball operation. 3. Install waved plate (6) and clutch plates (5). Start with
Replace the piston if the check ball is missing or falls out. a steel plate and alternate with lined plates.
D Align second clutch inner tangs.
Reassembly 4. Install spacer (4), with the fluted end toward clutch
plates.
1. Install piston assembly (10) into the second clutch 5. Install retaining ring (3), ring gear (2) and retaining
drum (11). ring (1).
D Lubricate the lip seal with transmission fluid. Use
the J–23080–A second clutch piston installer to
protect the outer piston lip seal.
NOTE: Lip of the seal should point toward front of
transmission.
D Remove the installer.
247RS007
3–4 Accumulator Piston

Disassembled View
244RS005
Legend (3) Spring

(1) Snap Ring (4) Piston Assembly
(2) Cover
Disassembly 2. Install the J–41096 cover remover and J–38584

adapter to center hole of cover.
1. Install the J–38559–A cover compressor on adapter D Use the J–23907 slide hammer to remove cover.
case.
3. Remove spring and piston assembly.
D Compress piston cover then remove snap ring.
242RW001
242RS007

Visual Check:
damaged part.
Reassembly
1. Place the J–38553 piston fitter into adaptor case and
push the piston into position, using suitable diameter
tube.
D Remove the piston fitter.
244RS006
2. Install spring and cover.

3. Install snap ring, using the J–38559–A compressor
tool.
D Install snap ring in groove.
D Remove the compressor tool.
242RS007
Reverse Clutch Piston And Center Support

Disassembled View
242RY001
Legend (9) Restrictor

(1) Retaining Ring (10) Retainer Plate
(2) Spring Seat (11) Plug
(3) Springs (12) Spring
(4) Piston Assembly (13) Overrun Lock Out Valve
(5) Center Support (14) Retainer Plate
(6) Gasket (15) Plug
(7) Transfer Plate (16) Spring
(8) Gasket (17) Reverse Lock Out Control Valve
Disassembly
1. Install the J–23327 compressor tool on spring seat,
then compress the spring seat.
D Remove retaining ring (1).
NOTE: Do not over–stress the springs and seat, as this
will cause damage to the spring seat.
D Remove the compressor tool.
247RS008 242RS005
2. Remove spring seat (2) and springs (3). 6. Install gasket transfer plate/adapter case (8), center
3. Remove piston assembly (4). support transfer plate (7), and gasket transfer
plate/center support (6).
4. Remove 8 bolts from center support (5), then remove
center support (5) from adapter case. 7. Install center support (5) with 8 bolts.
5. Remove gasket transfer plate/outer support (6), Torque : 25 N•m (18 lb ft)
center support transfer plate (7), and gasket transfer 8. Install piston assembly (4) into center support (5).
plate/adapter case (8).
9. Install twenty four springs (3), spring seat (2), and
6. Remove restrictor (9) from adapter case housing. retaining ring (1).
7. Remove retainer plate (10), plug (11), spring (12), and D Install the J–23327 compressor and compress
overrun lock out valve (13) from center support (5). spring seat (2) and springs (3), then seat snap ring
8. Remove retainer plate (14), plug (15), spring (16) and (1) in groove.
reverse lock out valve (17) from center support (5). D Remove the tool.

Visual Check:
damaged part.
Reassembly
1. Install reverse lock out valve (17) and spring (16) to
center support.
NOTE: Ensure correct assembly of valve. The spring
should be located over the long small diameter end.
2. Install plug (15) and retainer plate (14).
3. Install overrun lock out valve (13) and spring (12) to
center support.
NOTE: Ensure correct assembly of valve. The spring
should be located over the long small diameter end.
4. Install plug (11) and retainer plate (10).
5. Place restrictor (9) in the lube overdrive channel in the
adapter case housing.
Overrun Clutch And Turbine Shaft

Disassembled View
252RW005

(1) Snap Ring (9) Overrun Roller Clutch Cam
(2) Overdrive Carrier Assembly (10) Roller Clutch Assembly
(3) Sun Gear (11) Overrun Clutch Release Spring Retainer
(4) Turbine Shaft (12) Diaphragm Spring
(5) Snap Ring (13) Piston Assembly
(6) Backing Plate (14) Overrun Clutch Drum
(7) Clutch Plates (15) Turbine Shaft Seal Rings
Disassembly Inspection And Repair

1. Position overrun clutch assembly upright, using the Overdrive Carrier Check
overdrive internal gear as a support.
D Check pinion end play with a feeler gauge.
D Remove snap ring (1).
Clearance: 0.24mm–0.64mm (0.0094in–0.025in)
If clearance is outside specified value, replace overdrive
carrier assembly.
252RS009
2. Remove overdrive carrier assembly (2), sun gear (3)

and turbine shaft (4).
3. Remove snap ring (5), backing plate (6), and clutch 252RS011
plates (7). Visual Check:

4. Compress diaphragm spring with the J–23327–91
If any damage, deformation or local wear is found,
compressor, then remove snap ring (8).
replace the damaged part.
Reassembly
1. Install turbine shaft seal rings (15) with grease
(petroleum jelly).
252RS010
5. Remove overrun roller clutch cam (9) and roller clutch

assembly (10).
6. Remove overrun clutch release spring retainer (11)
and diaphragm spring (12).
7. Remove piston assembly (13) from overrun clutch 241RS008
drum (14).
8. Remove turbine shaft seal rings (15).
2. Install the J–38555 inner installer on the drum (14). 3. Install diaphragm spring (12).
D Pre–install piston assembly into J–38555 outer 4. Install overrun clutch release spring retainer (11) (lip
installer. faces upwards), overrun roller clutch assembly (10),
D Install overrun clutch piston assembly (13). Use the and cam (9).
outer installer while pushing piston into drum (14). 5. Place snap ring loosely on spring retainer.
D Remove the installer. D Hold the J–23327–91 compressor in a vise and
compress piston return spring with compressor.
D Set snap ring (8) in ring groove.
D Remove the compressor.
6. Install clutch plates (7), start with steel plate and
alternate with lined plates.
7. Install backing plate (6).
8. Install snap ring (5).
9. Install overdrive sun gear with countersink pointing
downwards.
10. Install the overdrive carrier assembly (2).
NOTE: Turn the assembly in a counter–clockwise
direction only until roller clutch enters the outer race.
After installation, rotate the assembly and listen for loose
rollers.
11. Install turbine shaft (4) and snap ring (1).
252RS012
252RS013
Main Data And Specification

Remarks
Model THM 4L30–E
Engine V6 3.5L 6VE1 DOHC
Type Automatic four speed overdrive in
4th gear lock–up clutch torque
converter
Shift control Hydraulic
Shift pattern Electronic
Control systems
Shift quality Electronic
Lock–up clutch Electronic
1st 2.856
2nd 1.618
Gear ratio 3rd 1.000
4th (O/D) 0.723
Reverse 2.000
Gear set Noiseless, high torque capability
Name ATF DEXRON–III
Oil used
Q’ty liter (qt) 8.6 (9.1)
Torque converter 2,100 ± 150 Stall speed (rpm)
Reverse clutch RC 4
Second clutch C2 6
Number of discs
Third clutch C3 6
Brake band Double wrap
Fourth clutch C4 2
Number of discs
Overrun clutch OC 1
Overdrive OFW 10 Number of rollers
Principal PFW 26 Number of sprags
Input sun gear 30
Pinion gear 19
Ravigneaux
g plan- Long pinion 23
etary gear set Ring gear 90
Long pinion 19 Number of teeth
Output sun gear 46
Sun gear 31
Overdrive
O d i plane-
l Pinion gear 24
tary gear set
Ring gear 81
E07RY00013
E07RY003
E07RY001
Special Tools
TOOL NO. TOOL NO.
TOOL NAME TOOL NAME
J–23075 J–23085–A
Spring compressor (For Selective washer
servo piston) gauging tool
J–23327–90
J–38450–A
Fourth clutch spring
Third clutch snap ring
compressor (Use with
compressor
J–23327)
J–23075–12
J–38553
Third clutch spring
3/4 Accumulator piston
compressor adapter
fitter
(Use with J–23075)
J–23084 J–41096
Third clutch piston Cover remover (Use
installer with J–38584)
J–23327 J–38584
Third clutch spring Slide hammer adapter
compressor (Use with J–23907)
J–23080–A
J–38554
Second clutch piston
Fourth clutch piston fitter
installer
TOOL NO. TOOL NO.

TOOL NAME TOOL NAME
J–38588
J–23082–01
Guide pins; adapter
Oil pump rotation tool
case to main case
J–38555 J–25025–B
Overrun clutch piston Guide pins; valve body
seal installer set to main case
J–3387–2
Guide pins; gasket and J–38428
transfer plate to valve Servo piston fitter
body
J–25022 J–23327–91
Turbine shaft puller (Use Overrun clutch spring
with J–24773–1) compressor
J–23129
J–38559–A
Oil seal remover (Use
3/4 Accumulator piston
with J–23907 and
cover compressor
J–38584)
J–38557 J–8763–02
Oil pump centering tool Holding fixture
TOOL NO.
ILLUSTRATION
TOOL NAME
J–36797
A/T extension housing
oil seal installer (Inside)
J–3289–20
Holding fixture base
J–29770–A
Pressure gauge
J–24773–1
End play fixture (Use
with J–25022)
J–23907
Slide hammer
4L30–E Parts List

Case And Associated Parts
241RY00001
Legend (17) Pin, 3–4 Accumulator Piston

(1) Torque Converter (18) Piston, 3–4 Accumulator
(2) Screw, Seal Ring Assembly (19) Ring, 3–4, Accumulator Piston
(3) Seal Ring Assembly, Converter Housing (20) Case, Adapter
(4) Screw, Converter Housing/Main Case (22) Connector, Electrical/Adapter Case
(5) Screw, Converter Housing/Oil Pump (23) Screw, Pan
(6) Housing, Converter (27) Restrictor, Oil
(7) Plug, Converter Housing (28) Gasket, Transfer Plate/Adapter
(8) Seal, O–Ring (29) Plate, Transfer Adapter/Center Support
(9) Wear Plate, Oil Pump Body (30) Support Assembly, Center
(10) Pump Assembly, Oil (31) Screw, Center Support
(11) Gasket (32) Ring, Oil Seal
(12) Washer, Thrust Selective (33) Seal, O–Ring Main Case
(13) Ring, Snap (34) Fitting, Cooler
(14) Cover, 3–4 Accumulator Piston (35) Fitting Assembly, Cooler
(15) Seal, O–Ring, 3–4 Accumulator (36) Case, Main
(16) Spring, 3–4 Accumulator Piston (37) Breather, Pipe
(38) Seal, O–Ring (75) Gasket, Bottom Pan/Main Case
(39) Reservoir (76) Gasket, Oil Drain or Overfill Screw
(42) Gasket, Extension Case (77) Screw, Oil Drain or Overfill
(43) Extension Assembly (78) Magnet, Chip Collector
(44) Seal, O–Ring/Speed Sensor (79) Filter Oil
(45) Sensor Assembly, Speed (80) Harness Assembly, Main Case
(46) Screw, Speed Sensor (82) Roller and Spring Assembly, Manual Detent
(50) Seal, Extension Assembly (84) Valve Body Assembly, Main Case
(52) Screw, Extension/Main Case (85) Ball, Check
(53) Spring, Parking Pawl Lock (86) Gasket, Main V.B./Transfer Plate
(54) Pawl, Parking Lock (87) Plate, Main V.B./Transfer
(55) Connector, Electrical/Main Case (88) Gasket, Transfer/Main Case
(56) Actuator Assembly, Parking Lock (89) Screw, Transfer Plate on V.B.
(57) Nut, Parking Lock Lever (90) Screw, Servo Cover
(58) Link, Manual Valve (91) Cover, Servo Piston
(59) Pin, Spring (92) Gasket, Cover/Servo Piston
(60) Lever, Parking Lock and Range Selector (93) Ring, Retaining Servo Piston
(61) Shaft, Selector (94) Clip, Servo Piston
(62) Seal, Selector Shaft (95) Nut, Servo Screw
(63) Mode Switch Assembly (96) Screw, Servo Piston
(64) Screw and Conical Washer Assembly (97) Piston, Servo
(65) Shield, Mode Switch (98) Seal, Ring/Servo Piston
(67) Pan, Bottom/Adapter Case (99) Spring, Cushion/Servo Piston
(68) Gasket, Bottom Pan/Adapter Case (100) Seat, Cushion Spring
(69) Harness Assembly, Adapter Case (101) Sleeve, Servo Piston Adjust
(70) Screw, Valve Body (102) Rod, Apply/Servo Piston
(71) Valve Body Assembly, Adapter Case (103) Spring, Return/Servo Piston
(72) Gasket, Adapter Valve Body (104) Gasket, Adapter Case/Transfer Plate
(73) Plate, Adapter Valve Body/Transfer (105) Powertrain Control Module
(74) Pan, Bottom/Main Case (106) Servo Piston Assembly
Pump Assembly
241RY003
Legend (215) Spring, Pressure Regulator Valve

(201) Gear, Oil Pump Drive (216) Seat, Spring/Pressure Regulator Valve
(202) Gear, Oil Pump Driven (217) Valve, Pressure Regulator
(203) Pin, Plug Converter Clutch Control (218) Isolator Valve
(204) Plug, Converter Clutch Control Valve (219) Spring, Isolator
(205) Spring, Converter Clutch Control Valve (220) Valve, Converter Clutch Regulator
(206) Valve, Converter Clutch Control (221) Spring, Converter Clutch Regulator
(207) Ring, Snap/Throttle Signal Accumulator (222) Sleeve, Converter Clutch Regulator
(208) Seat, Spring/Throttle Signal Accumulator (223) Pin, Retainer Sleeve
(209) Spring, Throttle Signal Accumulator (224) Valve, Enable
(210) Piston, Throttle Signal Accumulator (225) Spring, Enable Valve
(211) Pin, Boost Valve Sleeve (226) Spring Guide, Enable Valve
(212) Sleeve, Boost Valve (227) Pin, Enable Valve
(213) Valve, Boost (228) Pump Assembly
(214) Seat, Spring/Pressure Regulator Valve (229) Seal Ring, Plug
Valve Body Assemblies
244RS009
Legend (311) Spring, Valve Low Pressure Control

(301) Body, Valve Main Case (312) Valve, Low Pressure Control
(302) Pin, Spring (317) Ball, Check
(303) Solenoid Assembly, ON/OFF N.C. (318) Valve, 1–2 Accumulator Control
(304) Valve, 1–2 and 3–4 Shift (320) Valve, 1–2 Accumulator
(305) Spring, 1–2 and 3–4 (2–3) Shift (321) Washer, Waved PWM Solenoid
(306) Retainer, Valve (322) Pin, Solenoid PWM
(307) Solenoid Assembly, ON/OFF N.O. (323) Solenoid Assembly, Band Control PWM
(308) Valve, 2–3 Shift (324) Screen Assembly, PWM Solenoid
(309) Pin, Spring (325) Plug, Screen
(310) Plug, Valve Bore (326) Valve, Manual
243RY002
Legend (410) Spring, Feed Limit Valve

(401) Body, Valve/Adapter Case (411) Ring, Retainer
(402) Screw, Solenoid Force Motor (412) Valve, Feed Limit
(403) Retainer, Force Motor (413) Seal, O–Ring Plug Filter
(404) Solenoid, Force Motor (414) Plug, Screen
(405) Plug, 3–4 Accumulator (415) Screen Assembly, Force Motor
(406) Plug and Spring Retainer (416) Solenoid, Torque Converter Clutch, PWM
(407) Valve, 3–4 Accumulator (417) Retainer, Screen Plug
(409) Valve, 3–4 Accumulator Control (418) Bracket, PWM Solenoid
Overdrive Internal Components
252RW003
Legend (520) Plate, Waved/Overrun Clutch

(501) Retainer, 4th Clutch (521) Plate, Overrun Clutch (Steel)
(502) Plate, 4th Clutch (Steel) (522) Plate Assembly, Overrun Clutch (Lined)
(503) Plate Assembly, 4th Clutch (Lined) (523) Plate, Backing/Overrun Clutch
(504) Retainer And Ball Assembly, Check Valve (524) Ring, Snap/Overrun Clutch Housing
(505) Seal, O–Ring/Turbine Shaft (525) Carrier Assembly, Overdrive Complete
(506) Shaft, Turbine (526) Ring, Snap/Turbine Shaft/Carrier
(508) Ring, Oil Seal/Turbine Shaft (527) Bearing Assembly, Thrust
(510) Housing, Overrun Clutch (528) Gear, Overdrive Internal
(513) Piston, Overrun Clutch (529) Washer, Thrust/Internal Gear/Support
(514) Spring, Overrun Clutch Release (530) Ring, Snap/Adapter/4th Clutch Spring
(515) Retainer, Release Spring/Overrun Clutch (531) Retainer and spring assembly, 4th clutch
(516) Roller Assembly, Overdrive Clutch (532) Piston, 4th Clutch
(517) Cam, Overdrive Roller Clutch (533) Seal, 4th Clutch Piston (Inner)
(518) Ring, Snap/Overrun Clutch Hub (534) Seal, 4th Clutch Piston (outer)
(519) Gear, Overdrive Sun
Internal Components
247RW002
Legend (627) Plate Assembly, 2nd Clutch (Lined)

(608) Seal, Reverse Clutch Piston (Inner) (628) Spacer, 2nd Clutch
(609) Seal, Reverse Clutch Piston (Outer) (629) Ring, Retaining
(610) Piston, Reverse Clutch (630) Gear, Ring
(611) Spring, Piston Clutch (631) Washer, Thrust/2nd Clutch/3rd Clutch
(612) Seat, Spring/Reverse Clutch (632) Thrust Washer, Clutch Hub
(613) Ring, Retaining (634) Drum Assembly, 3rd Clutch
(614) Plate, Waved/Reverse Clutch (635) Seal, 3rd clutch piston (Inner)
(615) Plate, Reverse Clutch (Steel) (636) Washer, Retaining
(616) Plate Assembly, Reverse Clutch (Lined) (637) Seal, 3rd Clutch Piston (Outer)
(617) Plate, Reverse Clutch Pressure/Selective (638) Piston 3rd Clutch
(618) Drum Assembly, 2nd Clutch (639) Seat, Spring/3rd Clutch
(620) Seal, 2nd Clutch Piston (Inner) (640) Ring, Retaining
(621) Seal, 2nd Clutch Piston (Outer) (641) Plate, Spring Cushion/3rd Clutch
(622) Piston, 2nd Clutch (642) Plate, 3rd Clutch (Steel)
(623) Seat, Spring/2nd Clutch (643) Plate Assembly, 3rd Clutch (Lined)
(625) Plate, Waved/2nd Clutch (644) Washer, Thrust/Input Sun
(626) Plate, 2nd Clutch (Steel) (645) Bearing, Input Shaft/Gear Assembly
(646) Gear Assembly, Input Sun (658) Gear, Reaction Sun
(647) Race Assembly, Sprag (659) Drum, Reaction Sun
(648) Ring, Retaining/Sprag (664) Band Assembly, Brake
(649) Ring, Retaining (667) Seal, Ring/Wheel Parking Lock
(650) Cage Assembly, Sprag (668) Wheel, Parking Lock
(651) Bearing, Output Shaft/Input Sun (672) Wheel, Speed
(652) Washer, Output Shaft/Input Sun (673) Ring, Retaining
(653) Carrier Assembly, Planetary (675) Bearing, Thrust Assembly
Center Support Assembly
242RY002
Legend (704) Spring, Lockout

(701) Center Support (705) Valve, Overrun Lockout
(702) Retainer Plate (706) Valve, Reverse Lockout Control
(703) Plug, Lockout
Extension Housing Assembly Oil Seal

Extension Housing Assembly Rear Oil Seal and Associated Parts
220RY00010
Legend (3) Oil Seal

(1) Propeller Shaft (4) Mass
(2) End Nut and Companion Flange
1. Disconnect the propeller shaft (1) and mass (4) from 1. Install oil seal and apply engine oil to the oil seal outer
the extension housing assembly. surfaces.
2. Remove end nut and companion flange (2), using the 2. Apply the recommended grease (BESCO L2) or
companion flange holder J–8614–11. equivalent to the oil seal lip.
3. Use the oil seal installer J–39208 to install the rear
seal (3) to the extension housing assembly.
266RW001
3. Use the universal puller to remove the companion

flange and O–ring. 220RS016
4. Remove the oil seal from the extension housing

assembly.
4. Install the companion flange (2) and O–ring (2). 7. Connect the mass and propeller shaft to the
5. Use the companion flange holder J–8614–11 to install extension housing assembly and tighten to the
a new end nut (2) and tighten to the specified torque. specified torque.
Torque: 167 N·m (123 lb ft) Torque: 63 N·m 46 (lb ft)
6. Use the punch J–39209 to stake the end nut at two
spots.
staked portion of the end nut (2) after staking.
266RS001
266RW002
Extension Housing Assembly

Extension Housing Assembly and Associated Parts
260RY00006
Legend (2) Mass

(1) Propeller Shaft (3) Extension Housing Assembly
Removal
2. Raise and support vehicle with suitable stands.
3. Disconnect harness connectors and fuel pipe fix bolt.
Connector: speed sensor.
4. Removing the speedometer driven gear bushing and
driven gear, drain extension housing assembly fluid.
5. Remove propeller shaft (1) and mass (2).
NOTE: Apply alignment marks on the flange at both front
and rear sides.
6. Remove extension housing assembly (3) from the
vehicle.
Installation
1. Apply a thin coat of molybdenum disulfide grease to
the extension shaft spline as shown in the figure.
260RY00004
2. Install extension housing assembly (3) to the
transmission. Tighten extension housing assembly
bolts as shown in the figure.
261RY00001
3. Install speedometer driven gear bushing and driver

gear.
4. Connect harness connectors and fuel pipe fix bolt.
Connector: speed sensor.
5. Install propeller shaft (1) and mass (2).
6. Fill extension housing assembly fluid.

Extension Housing Assembly and Associated Parts
220RY00009
Legend (2) Companion Flange

(1) Speedometer Sensor, Speedometer Driven (3) Extension Housing Assembly
Gear and Plate
Removal 2. Tighten the new transfer flange nuts to the specified

torque.
1. Remove the speedometer sensor (1).
Torque
2. Remove the plate (1).
Companion flange: 167 N·m (123 lb ft)
3. Remove the speedometer driven gear bushing and
3. Use the punch J–39209 to stake the companion
driven gear (1).
flange nut (3) at two spots.
NOTE: Apply a reference mark to the driven gear bushing
before removal.
4. Remove rear companion flange (2), using the flange
companion holder J–8614–11 to remove the end nut.
266RS001
266RW001
5. Remove the rear companion flange.

NOTE: Use the universal puller to remove the rear
companion flange.
Installation
1. Install companion flange (2), using the companion
flange holder J–8614–11 to tighten the flange nuts to
the transfer case.
266RW002
266RW001
staked portion of the flange nut after staking.
4. Install the O–ring (7) to the speedometer driven gear
bushing (6).
5. Install the driven gear to the speedometer driven gear
bushing (6).
6. Install the speedometer driven gear assembly to the
extension housing assembly.
7. Install the plate (5) to the extension housing assembly
8. Install the speedometer sensor and tighten to the
specified torque.
225RY00003
Legend
(4) Bolt
(5) Plate
(6) Bushing
(7) O–ring
220RY00011
Legend (6) Ball

(1) Bearing Snap Ring (7) Speedometer Drive Gear
(2) Front Ball Bearing (8) Rear Ball Bearing
(3) Extension Shaft (9) Air Breather Pipe Collar
(4) Bearing Snap Ring (10) Extension Case
(5) Front Oil Seal
Disassembly 8. Remove extension shaft (3) from the front ball

bearing (2), using a bench press and bearing remover
1. Remove front oil seal (5) from the extension housing J–22912–01.
assembly.
220RY00007
220RY00005 9. Remove air breather pipe collar (9) from the

2. Remove front snap ring (4), use a pair of snap ring extension housing assembly.
3. Remove the extension shaft with ball bearing from the
extension case (10). Reassembly
4. Remove rear ball bearing (8), using a bench press 1. Install air breather pipe collar (9) to the extension
and the bearing remover J–22912–01. housing assembly.
CAUTION: PUT THE AIR BREATHER PIPE COLLAR
INTO THE EXTENSION CASE AS MATCHING THE
PROTRUSION OF THE AIR BREATHER PIPE
COLLAR WITH THE DEPRESSION OF THE
EXTENSION CASE.
2. Install front ball bearing (2) to the extension shaft (3),
using the ball bearing installer J–22912–01.
3. Install bearing snap ring (1), using a pair of snap ring
pliers.
4. Install ball (6).
5. Install speedometer drive gear (7).
6. Use the ball bearing installer J–22912–01 to install
the rear ball bearing (8).
7. Install the extension shaft with ball bearing to the
extension case (10).
8. Install front snap ring (4).
220RY00006
5. Remove speedometer drive gear (7).

6. Remove ball (6).
7. Remove bearing snap ring (1), using a pair of snap
ring pliers.
9. Install front oil seal (5). 2. If the measured value exceeds the specified limit, the
ball bearing must be replaced.
CAUTION: Hammering the outside of the oil seal
equally, install it to the extension case entirely. Limit : 0.2 mm (0.008 in)
220RY00008 226RS043
Legend
(1) Front Oil Seal
(2) Extension Case

1. Make the necessary repair or parts replacement if
wear, damage or any other abnormal conditions are
found during inspection.
2. Wash all parts thoroughly in clean solvent. Be sure all
old lubricant, metallic particles, dirt, or foreign
material are removed from the surfaces of every part.
Apply compressed air to each oil feed port and
channel in each case half to remove any obstructions
or cleaning solvent residue.
Bearings
1. Inspect the condition of all bearings. Wash bearings
thoroughly in a cleaning solvent. Apply compressed
air to the bearings.
NOTE: Do not allow the bearings to spin. Turn them
slowly by hand. Spinning bearings may damage the
rollers.
2. Lubricate the bearings with a light oil and check them
for roughness by slowly turning the race by hand.
Ball Bearing Play
1. Use a dial indicator to measure the ball bearing play.

Oil capacity 0.185 lit. (0.195 U.S. quart)
Type of lubricant ATF DEXRON–III
220RY00012
Special Tools
PART NO.
ILLUSTRATION
PART NAME
J–22912–01
Bearing
remover/installer
J–39209
Punch; end nut
J–39208
Rear oil seal installer
J–8614–11
Flange holder
TRANSMISSION CONTROL SYSTEM (4L30–E) 7A1–1
TROOPER
TRANSMISSION
TRANSMISSION CONTROL SYSTEM (4L30–E)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 7A1–2 Diagnostic Trouble Code (DTC)
General Description . . . . . . . . . . . . . . . . . . . . . 7A1–2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–24
Electronic Control Diagram . . . . . . . . . . . . . 7A1–3 DTC P0218 Transmission Fluid Over
Powertrain Control Module (PCM) . . . . . . . 7A1–4 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–25
Control System Diagram . . . . . . . . . . . . . . . 7A1–5 DTC P0705 Transmission Range Switch
Shift Control . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–6 (Mode Switch) Illegal Position . . . . . . . . . . . . 7A1–27
Band Apply Control . . . . . . . . . . . . . . . . . . . . 7A1–6 DTC P0706 Transmission Range Switch
Torque Converter Clutch Control (Mode Switch) Performance . . . . . . . . . . . . . . 7A1–30
(Electronically Controlled Capacity DTC P0711 Transmission Fluid Temperature
Clutch = ECCC) . . . . . . . . . . . . . . . . . . . . . . 7A1–6 (TFT) Sensor Performance . . . . . . . . . . . . . . 7A1–33
Line Pressure Control . . . . . . . . . . . . . . . . . . 7A1–6 DTC P0712 Transmission Fluid Temperature
On–Board Diagnostic System . . . . . . . . . . . 7A1–6 (TFT) Sensor Circuit Low Input . . . . . . . . . . . 7A1–36
Fail Safe Mechanism . . . . . . . . . . . . . . . . . . . 7A1–6 DTC P0713 Transmission Fluid Temperature
Torque Management Control . . . . . . . . . . . . 7A1–6 (TFT) Sensor Circuit High Input . . . . . . . . . . . 7A1–39
ATF Warning Control . . . . . . . . . . . . . . . . . . . 7A1–6 DTC P0719 Brake Switch Circuit Low
ABS Control . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–6 (Stuck On) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–42
Reverse Lock Out Control . . . . . . . . . . . . . . 7A1–6 DTC P0722 Automatic Transmission Output
Speed Sensor (OSS) Low Input . . . . . . . . . . 7A1–45
Downhill Control . . . . . . . . . . . . . . . . . . . . . . . 7A1–6
DTC P0723 Automatic Transmission Output
Uphill Control . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–6
Speed Sensor (OSS) Intermittent . . . . . . . . . 7A1–48
Shift Mode Control . . . . . . . . . . . . . . . . . . . . . 7A1–7
DTC P0724 Brake Switch Circuit High
Gear Shift Control . . . . . . . . . . . . . . . . . . . . . 7A1–8
Winter Drive Mode . . . . . . . . . . . . . . . . . . . . . 7A1–9 (Stuck Off) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–51
Backup Mode . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–9 DTC P0730 Gear Error Without Input Speed 7A1–53
Functions of Input / Output Components . . 7A1–10 DTC P0742 Torque Converter Clutch (TCC)
System Stuck On . . . . . . . . . . . . . . . . . . . . . . . 7A1–56
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–11
DTC P0748 Pressure Control Solenoid (PCS)
Electronic Diagnosis . . . . . . . . . . . . . . . . . . . 7A1–11
(Force Motor) Circuit Electrical . . . . . . . . . . . 7A1–58
Check Trans Indicator . . . . . . . . . . . . . . . . . . 7A1–11
DTC P0751 Shift Solenoid A Performance
Diagnostic Check . . . . . . . . . . . . . . . . . . . . . . 7A1–11 (Stuck OFF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–60
“Check Trans” Check . . . . . . . . . . . . . . . . . . 7A1–12 DTC P0752 Shift Solenoid A Performance
Tech 2 OBD II Connection . . . . . . . . . . . . . . 7A1–13 (Stuck ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–62
Transmission Data . . . . . . . . . . . . . . . . . . . . . 7A1–18 DTC P0753 Shift Solenoid A Electrical . . . . . 7A1–64
OBD II Diagnostic Management System . . 7A1–19 DTC P0756 Shift Solenoid B Performance
16 – Terminal Data Link Connector (DLC) . 7A1–20 (Stuck OFF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–67
Malfunction Indicator Lamp (MIL) . . . . . . . . 7A1–21 DTC P0757 Shift Solenoid B Performance
Types Of Diagnostic Trouble Codes (DTCs) 7A1–21 (Stuck ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–69
Clear DTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–21 DTC P0758 Shift Solenoid B Electrical . . . . . 7A1–71
DTC Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–22 DTC P1850 Brake Band Apply Solenoid
PCM Precaution . . . . . . . . . . . . . . . . . . . . . . . 7A1–22 Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–75
Information On PCM . . . . . . . . . . . . . . . . . . . 7A1–22 DTC P1860 TCC PWM Solenoid Electrical . 7A1–79
Intermittent Conditions . . . . . . . . . . . . . . . . . 7A1–22 DTC P1870 Transmission Component Slipping
Transmission And PCM Identification . . . . . 7A1–23 (TCC Stuck OFF) . . . . . . . . . . . . . . . . . . . . . . . 7A1–82
Isuzu Trooper . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–23 Connector List . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1–84
7A1–2 TRANSMISSION CONTROL SYSTEM (4L30–E)

WARNING: THIS VEHICLE HAS A SUPPLEMENTAL The 4L30–E is a 4–speed fully automatic transmission. It
RESTRAINT SYSTEM (SRS). REFER TO THE SRS uses a microcomputer as a control unit to judge running
COMPONENT AND WIRING LOCATION VIEW IN conditions including throttle opening rate and vehicle
ORDER TO DETERMINE WHETHER YOU ARE speed, then it sets the shifting point in the optimum timing
PERFORMING SERVICE ON OR NEAR THE SRS so that best driving performance can be achieved.
COMPONENTS OR THE SRS WIRING. WHEN YOU In addition, the built–in shift mode select function can
ARE PERFORMING SERVICE ON OR NEAR THE SRS select three shift modes according to the driver’s
COMPONENTS OR THE SRS WIRING, REFER TO preference:
THE SRS SERVICE INFORMATION. FAILURE TO D Normal mode –Normal shift pattern.
FOLLOW WARNINGS COULD RESULT IN POSSIBLE D Winter mode –Starts in 3rd gear to reduce slippage on
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR ice or snow.
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. D Power mode has a delayed upshift for when more
powerful acceleration is required.
proper location. When you replace a fastener, use Also, the built–in fail safe function (“backup mode”)
ONLY the exact part number for that application. assures driving performance even if the vehicle speed
ISUZU will call out those fasteners that require a sensor, throttle signal or any solenoid fails.
replacement after removal. ISUZU will also call out Further, the self–diagnostic function conducts diagnosis
the fasteners that require thread lockers or thread in a short time when the control system fails, thus
sealant. UNLESS OTHERWISE SPECIFIED, do not improving serviceability.
use supplemental coatings (Paints, greases, or other The major features of 4L30–E are as follows:
corrosion inhibitors) on threaded fasteners or D A compact structure consisting of 2 sets of planetary
fastener joint interfaces. Generally, such coatings gears and flat torque converter.
adversely affect the fastener torque and the joint D Electronic control selects the optimum shift mode
clamping force, and may damage the fastener. When according to the driving conditions.
you install fasteners, use the correct tightening D Electronic control maintains the optimum hydraulic
sequence and specifications. Following these pressure for clutch, band brake as well as
instructions can help you avoid damage to parts and transmission so that shift feeling is improved.
systems.
D Two sets of planetary gears reduce friction of power
train.
Also, a lockup mechanism in the torque converter
reduces fuel consumption.
D Wide gear ratio and high torque rate of torque
converter provide excellent starting performance.
Electronic Control Diagram
C07RY00034
C07RY002
Control System Diagram
C07RY00033
Shift Control The vehicle can still be driven, but the driver must use the
The transmission gear is shifted according to the shift select lever to shift gears.
pattern selected by the driver. In shifting gears, the gear
ratio is controlled by the ON/ OFF signal using the shift
Torque Management Control
solenoid A and the shift solenoid B. The transmission control side sends the absolute spark
advance signal to the engine control side while the
Band Apply Control transmission is being shifted. This controls the engine
The band apply is controlled when in the 3–2 downshift spark timing in compliance with the vehicle running
(engine overrun prevention) and the garage shift (shock condition to reduce the shocks caused by the change of
control). speed.
The band apply solenoid is controlled by the signal from
the Pulse Width Modulation (PWM) to regulate the flow of
ATF Warning Control
the oil. The oil temperature sensor detects the ATF oil
temperature to control the oil temperature warning, TCC,
Torque Converter Clutch Control and the winter mode.
(Electronically Controlled Capacity Clutch
= ECCC) ABS Control
When the select lever is at “L” or “R” range, a signal is sent
The clutch apply is controlled by moving the converter
to the ABS controller as one of the ABS control
clutch valve by commanding Torque Converter Clutch
conditions.
(TCC) solenoid using the PWM signal.
Line Pressure Control Reverse Lock Out Control

With the selector lever in reverse position, the PCM will
The throttle signal allows the current signal to be sent to
not close the PWM solenoid until the vehicle is below 15
the force motor. After receiving the current signal, the
km/h (9.3 mph), thus preventing reverse engagement
force motor activates the pressure regulator valve to
above this speed.
regulate the line pressure.
On–Board Diagnostic System Downhill Control

This mode is automatically activated from “NORMAL”
Several malfunction displays can be stored in the
mode only when downhill conditions are recognized.
Powertrain Control Module (PCM) memory, and read out
The shift pattern is identical to “NORMAL” mode except
of it afterward.
3-4 and 4-3 shift lines at low throttle modified to get engine
The serial data lines, which are required for the testing of
braking on a larger speed range.
the final assembly and the coupling to other electronic
ECCC lines unchanged compared to “NORMAL” mode.
modules, can be regulated by this function.
Fail Safe Mechanism Uphill Control

When Uphill condition are recognized the 2-3 and 3-4 shift
If there is a problem in the transmission system, the PCM
and TCC apply are down only when the engine torque is
will go into a “backup” mode.
sufficient in order to avoid shift hunting.
Shift Mode Control
F07RX001
Gear Shift Control
F07RT034
Winter Drive Mode

1. Operation
The winter switch will operate when switched on after
all of the following conditions are present:
Conditions:
a. The select lever position is “D” range only.
b. Vehicle speed is 7 mph (11 km/h) or less.
c. Transmission oil temperature is 130°C (266°F) or
less.
d. Accelerator opening is at 8% or less.
2. Cancel Release
1. Cancellation by driver
a. Turning off the winter drive mode switch
b. Shifting select position to “3”, “2”, or “L” (winter
drive mode is not canceled by selecting “D”, “N”,
“R”, or “P”).
c. Ignition key is turned off.
2. Automatic cancellation
a. When vehicle runs at 21mph (34 km/h) or more
for 1 second or more
b. When transmission oil temperature reaches
130°C (266°F) or above
NOTE: The mode returns to normal drive mode or power
drive mode after the winter drive mode is canceled.
Backup Mode
If a major system failure occurs which could affect safety
or damage the transmission under normal vehicle
operation, the diagnostic system detects the fault and
overrides the Powertrain Control Module (PCM).
The “CHECK TRANS” light flashes to alert the driver, and
the transmission must be manually shifted as follows:
Select lever position Gear Ratio Selected
D 4 (Fourth)
Manual 3 4 (Fourth)
Manual 2 3 (Third)
Manual L 1 (First)
R Reverse
Shifts are firmer to prevent clutch slip and consequent

wear. The fault should be corrected as soon as possible.
Functions of Input / Output Components

Components Function
Speed sensor Senses rotation of output shaft and feeds the data to Powertrain Control Module
(fixed to transmission) (PCM).
Throttle position sensor Senses the extent of throttle valve opening and the speed of the throttle valve
(TPS) lever motion to open the valve. Feeds the data to PCM.
(fixed to engine)
Brake switch Senses whether the driver has pressed the brake pedal or not and feeds the
I (fixed to brake pedal) information to PCM.
N
P Mode switch (fixed to Senses the select lever position, and feeds the information to PCM.
U transmission)
T Power drive switch Senses whether the driver has selected the power mode, and feeds the
(fixed to front console) information to PCM.
S
T/M oil temperature sensor Senses the T/M oil temperature and feeds the data to PCM
I
G Engine coolant tempera- Senses the engine coolant temperature, and feeds the data to PCM.
N ture sensor
A Engine speed signal Feeds the signals monitoring engine speed to PCM from crank angle sensor.
L
Air conditioning information Senses whether the air conditioner has been switched on or not, and feeds the
information to PCM.
Winter switch (fixed to front Senses whether the driver has selected the winter mode, and feeds the
console) information to PCM.
Cruise controller (Over- Downshift takes place when overdrive OFF signal is received from auto cruise
drive OFF signal) controller integrated in PCM.
Shift solenoid A, B Selects shift point and gear position suited to the vehicle running condition on
the basis of PCM output.
S
O Band apply solenoid Controls oil flow suited to the vehicle running condition on the basis of PCM
O L output.
U E Torque Converter Controls clutch apply suited to the vehicle running condition on the basis of PCM
T N Clutch PWM solenoid output.
P O
U I Force motor Adjusts the oil pump delivery pressure to line pressure suited to the vehicle
T D (Pressure regulator running condition on the basis of PCM output.
valve)
S Power drive mode lamp Informs the driver whether the vehicle is in power mode or not.
I
G Winter drive mode lamp Informs the driver whether the vehicle is in winter mode or not.
N CHECK TRANS lamp Informs the driver of failure in the system.
A
L ATF warning lamp Lights when ATF oil temperature rises.
ABS signal When the select lever is at “Reverse” or “L” range, sends a signal to the ABS
controller as one of the ABS control conditions.
Diagnosis 2. Turn on the ignition but not the engine.

3. Push “F0” on Tech 2 to see the Diagnostic Trouble
Electronic Diagnosis Code (DTC):
How To Diagnose The Problem 4. Do you have a DTC?
YES: write down all code numbers and do the DTC
1. To avoid incorrect diagnostics, this book needs to be CHECK
followed accurately. Unless stated, do not jump
NO: the DTC can not help you finding the problem.
directly to a section that could contain the solution.
Some important information may be missed. 1. GOTHROUGH “CHECK TRANS” CHECK
2. The sections in CAPITALS and bold are the main 2. IF it is flashing and the flash is 0.2 seconds ON
sections that can be found in the contents. and 0.2 seconds OFF, this means that you should
3. The GOTO “SECTION” means to continue to check have a DTC stored. Please recheck GOTO
going to the “section”. DIAGNOSTIC CHECK and if you find the same
problem, replace the Powertrain Control Module
4. The GOTHROUGH “SECTION” means to go
(PCM).
through the “section” and then to go back to the place
the GOTHROUGH was written. Normal
5. BASIC ELECTRIC CIRCUITS:
You should understand the basic theory of electricity.
This includes the meaning of voltage, amps, ohms,
and what happens in a circuit with an open or shorted
wire. You should also be able to read and understand
wiring diagrams.
Check Trans Indicator

Find CHECK TRANS indicator and verify if it is
A. Flashing: GOTO DIAGNOSTIC CHECK.
B. Staying on: GOTHROUGH CHECK TRANS
CHECK.
C. Is never ON when the ignition key is turned on:
GOTHROUGH CHECK TRANS CHECK
D. Is ON during 2 seconds at ignition but OFF after:
Normal operation. No DTC or malfunction.
C07RY005
Abnormal
821RW018
Diagnostic Check
This test determines if the transmission or its input or
output connections or sensors are failing. C07RY004
1. Connect the Tech 2: GOTHROUGH Tech 2 OBD II

CONNECTION.
“Check Trans” Check Abnormal

1. Indicator it is ON during 2 seconds at ignition (or when
the engine is cranked) but it is OFF after the engine
starts. The indicator is working normally GOTO
DIAGNOSTIC CHECK.
C07RY004
3. Indicator it is staying ON always when Ignition is ON.

1. This means that connection between the lamp
and the PCM is shorted to ground.
821RW018
2. Verify if instrument panel terminal 3 (WO/TOD) or
6 (WO/TOD) of connector I–9 is shorted to
Normal ground.
3. Verify if the PCM connector J2 (RED) terminal 46
is shorted to ground.
4. Verify that the instrument panel terminal 15
(WO/TOD) or 26 (W/TOD) of connector I–9 is
connected to battery.
5. IF problem solved: GOTO CHECK TRANS
INDICATOR.
NO:Replace Powertrain Control Module (PCM).
4. Indicator it is staying OFF with the ignition ON (engine
OFF).
1. This means that connection between the lamp
and the PCM is shorted to battery or opened.
2. Verify if instrument panel terminal 3 (WO/TOD) or
6 (WO/TOD) of connector I–9 is shorted to
battery or open.
3. Verify if the PCM connector J2 (RED) terminal 46
C07RY005
is shorted to battery or open.
2. Indicator it is flashing and the flash is 0.2 seconds ON
and 0.2 seconds OFF always when ignition is on 4. Verify that the instrument panel terminal 15
(engine cranked or not). This means that there is a (WO/TOD) or 26 (W/TOD) of connector I–9 is
malfunction. GOTO DIAGNOSTIC CHECK. connected to battery. If not, check the fuses and
the connections (terminal 10 of connector H–25)
voltage.
5. IF problem solved: GOTO CHECK TRANS
INDICATOR.
NO: Replace Powertrain Control Module (PCM).
D07RY00009
Tech 2 OBD II Connection 2. SAE 16/19 adaptor (3000098) (1), RS 232 loop
In order to access OBD II Powertrain Control Module back connector (3000112) (2), and PCMCIA card
(3000117) (3).
(PCM) data, use of the Tech 2 scan tool kit (7000086) is
required.
1. The electronic diagnosis equipment is composed of:
1. Tech 2 hand held scan tool unit (7000057) and
DLC cable (3000095).
F07RW033
901RW176
2. Connecting the TECH2
901RW180
Legend (3) SAE 16/19 Adapter

(1) PCMCIA Card (4) DLC Cable
(2) RS 232 Loop Back Connector (5) Tech 2
D Before operating the Isuzu PCMCIA card with the 2. Connect the SAE 16/19 adapter (3) to the DLC
Tech 2, the following steps must be performed: cable (4).
1. The Isuzu 2000 System PCMCIA card (1) inserts 3. Connect the DLC cable to the Tech 2 (5)
into the Tech 2 (5).
5. Connect the Tech 2 SAE 16/19 adaptor to the 8. The power up screen is displayed when you
vehicle DLC. power up the tester with the Isuzu systems
PCMCIA card. Follow the operating procedure
below.
821RW021

060RY027
060RW009
NOTE: The RS232 Loop back connector is only to use for

diagnosis of Tech 2 and refer to user guide of the Tech 2.
Once the test vehicle has been identified an “Application
(Powertrain) Menu” screen appears. Please select the
appropriate application.
The following table shows, which functions are used for
the available equipment versions.
F0: Diagnostic Trouble Codes
F0: Read DTC Info Ordered By Priority
F1: Clear DTC Information
F2: DTC Information
F1: Data Display
F0: Transmission Data
F1: Output Driver Data
F2: Snap Shot
F3: Actuator Tests
F0: Lamps
F0: Check Light
F1: Winter Drive Lamp
F2: Power Drive Lamp
F3: AT Oil Temperature Lamp
F1: Solenoids
F0: Solenoid 1-2/3-4 Test
F1: Solenoid 2-3 Test
F2: TCC Solenoid
F3: Band Apply Solenoid
F4: Pressure Control Solenoid (PCS)
F4: Function Tests
F0: Reset Oil Life Monitor
060RY026
Diagnostic Trouble Codes Lamps
The purpose of the “Diagnostic Trouble Codes” mode is to You can operate the lamps by pressing the ON and OFF
display stored PCM trouble codes. buttons.
When “Diagnostic Trouble Codes” is selected an Preconditions: none
“Application Menu” screen appears. Solenoid
Clear DTC Information Solenoid 1-2/3-4, Solenoid 2-3, TCC Solenoid
The purpose of the “Clear DTC Information” mode is to You can operate the solenoids by pressing the ON and
command the clearing of stored PCM trouble codes. OFF buttons.
When “Clear DTC Information” is selected, a “Clear DTC Preconditions: P–N position, no vehicle speed, no engine
Information”, warning screen appears. This screen speed
informs you that by cleaning DTC’s, “all stored DTC Band Apply Solenoid
information in controller will be erased”. You can operate the solenoid by pressing the ON and
Do you want to clear DTC’s (Yes/No). OFF buttons.
Press either the Yes or No key when answering. Preconditions: P-N position, idle engine speed, no vehicle
After clearing codes, confirm system operation by test speed.
driving the vehicle. Pressure Control Solenoid (PCS)
Allow the vehicle to shift through all four forward gears in a You can set desired PCS Current using the UP (+25) and
manner which attempts to repeat the failure condition. DOWN (–25) button. The PC Solenoid Data informs
NOTE: When the trouble has not been repaired and the about PCS Current, Pressure and Duty Cycle.
trouble code cannot be erased, check the vehicle again. Preconditions: P–N position, no engine speed, no vehicle
speed
DTC Information
Reset Oil Life Monitor
When “DTC Information” is selected, an “Application
Displays parameter “Oil Life Monitor” and resets to 100%
Menu” appears with a list of DTC information function
if Yes-button is pressed on Reset-question. “No” leaves
keys addressing DTC specifics and their origins.
test.
Function key selections may vary for particular vehicle
Preconditions: no vehicle speed, no engine speed
and/or system.
Data Display
The purpose of the “Data Display” mode is to
continuously monitor data parameters.
The current actual values of all important sensors and
signals in the system are display through F1 mode.
When “Data Display” is selected an “Application Menu”
appears. Please select either “Engine” or “Transmission
Data Display”.
See “Transmission Data” on next page.
Snapshot
When “Snapshot” is selected an “Application Menu”
appears.
When “Transmission Snapshot” application is selected
from the “Application Menu”, a “Snapshot Menu”
appears, displaying several options. “Snapshot” options
may vary from one system to another.
“Snapshot” allows a recording of all vehicle parameters.
There parameters may then be replayed at a future point
in time.
This action allows you to focus on making the condition
occur, rather than trying to view all of the data in
anticipation of the fault. The snapshot will collect
parameter information around a trigger point that you
select.
When a snapshot is taken. It is recorded onto the
PCMCIA memory card. When the Tech 2 is powered
down. Snapshots are not lost.
Actuator Tests
The purpose of “Actuator Tests” mode is to check for
correct operation of electronic system actuators.
Transmission Data
Item Unit Engine running at idle
Ignition Voltage V 12.8 ∼ 14.1 V
Engine Speed RPM 750 ∼ 900 RPM
Vehicle Speed km/h, MPH 0 MPH
AT Output Speed (Automatic Transmission) RPM 0 RPM
AT Input Speed Ratio (Automatic Transmission) 0.0
Throttle Position % 0%
AT Oil Temperature (Automatic Transmission) °C, °F 70 ∼ 80°C (158 ∼ 176°F)
Transmission Temperature °C, °F 75 ∼ 110°C (167 ∼ 230°F)
AT Oil Temperature Lamp (Automatic Transmission) Off, On Off
AT Oil Life Monitor (Automatic Transmission) % 100 %
AT Oil Life Lamp (Automatic Transmission) Off, On Not used
Commanded Gear 1
Current Gear 1
Mode Switch A Inactive, Active Active
Mode Switch B Inactive, Active Inactive
Mode Switch C Inactive, Active Inactive
Mode Switch G Inactive, Active Active
Selector Position Park
1–2 Shift Solenoid A Off, On Off
2–3 Shift Solenoid B Off, On On
Solenoid Brake Band Off, On Off
TCC Slip Speed RPM 750 ∼ 900 RPM
TCC Solenoid Off, On Off
TCC Duty Cycle % 0%
PCS Current (Pressure Control Solenoid) A approx. 1.0 A
PCS Duty Cycle (Pressure Control Solenoid) % approx. 45 %
Desired PCS Pressure (Pressure Control Solenoid) kPa 43 ∼ 52 kPa
Shift Pressure kPa 43 ∼ 52 kPa
Brake Switch Off, On On
Kickdown Switch On, Off Not used
Winter Switch On, Off Off
Winter Drive Lamp Off, On Off
Power Switch Power Drive Normal
Normal
Power Drive Lamp Off, On Off
Emergency Mode Off, On Off
ABS Status On, Off Off
OBD II Diagnostic Management System

Powertrain Control Module (PCM) Location
826RY001 826RY002
Class 2 Serial Data Bus

OBD II technology requires a much more sophisticated TROOPER previously used a 5 volt data bus called
PCM than does OBD I technology. The OBD II PCM UART, which is an acronym for “Universal Asynchronous
diagnostic management system not only monitors Receive and Transmit”. When neither the vehicle’s
systems and components that can impact emissions, but control module nor the diagnostic tool, such as a Tech 2,
they also run active tests on these systems and are “talking,” the voltage level of the bus at rest is 5 volts.
components. The decision making functions of OBD II The two computers talk to each other at a rate of 8,192
PCMs have also greatly increased. To accommodate this bits per second, by toggling or switching the voltage on
expansion in diagnostic complexity, Isuzu engineers have the data bus from 5 volts to ground.
designed the Class 2 serial data bus, which meets SAE Class 2 data, which is used on OBD II vehicles, is quite
J1850 recommended practice for serial data. different. Data is transferred at a rate of 10.4 kilobits per
“Serial Data” refers to information which is transferred in a second, and the voltage is toggled between zero and 7
linear fashion – over a single line, one bit at a time. A “Data volts.
Bus” is an electronic pathway through which serial data
travels.
C07RT006
Class 2 data is also pulse width modulated. Each bit of

information can have one of two lengths: long or short. On
the other hand, UART data bits come in only one length
(short). The pulse width modulation of Class 2 data allows
better utilization of the data line.
The message carried on Class 2 data streams are also
prioritized. This means that if two devices try to
communication on the data line at the same time, only the
higher priority message will continue. The device with the
lower priority message must wait.
NOTE: The Class 2 data wire is always terminal 2 of the
new 16–terminal Data Link Connector (DLC).
16 – Terminal Data Link Connector (DLC)

OBD II standardizes Data Link Connector (DLC)
configurations. The DLC, formerly referred to as the
ALDL, will be a 16–terminal connector found on the lower
left side of the driver’s side instrument panel. All
manufacturers must conform to this 16–terminal 821RW021
standard.
Lamp (MIL) for emissions related DTCs. DTCs fall into
four categories: A, B, C, and D; only types A and B are
emission related The following descriptions define these
categories:
TYPE A
Will store the DTC and turn on the MIL (“Check Engine”
lamp) on the first trip in which an emission related
diagnostic test has run and reported a “test failed” to the
Diagnostic Executive.
TYPE B
Will store the DTC and turn on the MIL on the second
consecutive trip in which an emission related diagnostic
test has run and reported a “test failed” to the Diagnostic
Executive. After one failure, the type B DTC is “armed,”
or prepared to store a history code and turn on the MIL if
a second failure occurs. One passed test will disarm a
type B DTC. Some special conditions apply to misfire and
fuel trim DTCs. For a type B DTC to store and turn on the
MIL, two ignition cycles are required.
810RT022
PIN 1 – DIAG. SW TYPE C

Will store the DTC and turn on a “SERVICE” lamp
PIN 2 – J1850 Bus + L line on 2–wire systems, or
(“Check Trans” lamp) on the first trip that a non emission
single wire (Class 2)
related diagnostic test has run and reported a “test failed”
PIN 3 – (Not used) to the Diagnostic Executive. This type of DTC will be used
PIN 4 – Chassis ground pin in future applications.
PIN 5 – Signal ground pin
TYPE D
PIN 6 – (Not used)
Will store a DTC but will not turn on the MIL on the first
PIN 7 – ABS diagnostic enable trip that a non emission related diagnostic test has run
PIN 8 – TOD diagnostic enable and reported a “test failed” to the Diagnostic Executive.
PIN 9 – Primary UART These codes can be very helpful for vehicle service when
PIN 10 – (Not used) the driver may comment about a condition, but the MIL did
PIN 11 – (Not used) not turn on.
PIN 12 – ABS diagnostic or CCM diagnostic enable
PIN 13 – SIR diagnostic enable Clear DTC
PIN 14 – (Not used) NOTE: If you clear the DTC (Diagnostic Trouble Codes)
PIN 15 – (Not used) you will not be able to read any codes recorded during the
PIN 16 – Battery power from vehicle unswitched (4 last occurrence.
AMP MAX.)
NOTE: To use the DTC again to identify a problem, you
will need to reproduce the fault or the problem. This may
Malfunction Indicator Lamp (MIL) require a new test drive or just turning the ignition on (this
depends on the nature of the fault).
The Malfunction Indicator Lamp (MIL) looks the same as
the MIL you are already familiar with (“CHECK ENGINE” 1. IF you have a Tech 2:
lamp). However, OBD II requires that it illuminate under a 1. Connect the Tech 2 if it is still not connected
strict set of guidelines. Basically, the MIL is turned on GOTHROUGH Tech 2 OBD II CONNECTION.
when the PCM detects a DTC that will impact the vehicle’s 2. Push “F1: Clear DTC Information” in the
emissions. Application Menu and answer “Yes” to the
The MIL is under the control of the Diagnostic Executive. question “Do you want to clear DTC’s?”
The MIL will be turned on if a component or system which
has an impact on vehicle emissions indicates a a. When a malfunction remains as it is the Tech 2
malfunction or fails to pass an emissions–related displays “4L30E CODES NOT CLEARED”. This
diagnostic test. It will stay on until the system or means that the problem is still there or that the
recovery was not done. Please GOTO DTC
component passes the same test, for three consecutive
CHECK.
trips, with no emissions–related faults.
b. When a malfunction has been repaired and the
Types Of Diagnostic Trouble Codes (DTCs) recovery is done. The Tech 2 displays “4L30E
CODES CLEARED”.
The Diagnostic Executive classifies Diagnostic Trouble
Codes (DTCs) into certain categories. Each type has 2. IF you have no Tech 2:
different requirements to set the code, and the Diagnostic To clear the DTC, remove Fuse “PCM” (F13, 30A) for
Executive will only illuminate the Malfunction Indicator at least 10 seconds.
DTC Check Information On PCM

1. Diagnostic Trouble Codes (DTC) have been identified 1. The Powertrain Control Module (PCM) is located in
by Tech 2. the center console and is the control center of the
2. You have written the list of the DTCs. The order of the electronic transmission control system.
malfunctions has no meanings for this PCM. Usually 2. The PCM must be maintained at a temperature below
only one or two malfunctions should be set for a given 85° (185°F) at all times. This is most essential if the
problem. vehicle is put through a paint baking process. The
3. Check directly the DTCs you identified. The DTCs are PCM will become inoperative if its temperature
sorted by number. Refer to Diagnostic Trouble Code exceeds 85°C (185°F). Therefore, it is
(DTC) Identification in this section. recommended that the PCM be removed or that
temporary insulation be placed around the PCM
PCM Precaution during the time the vehicle is in a paint oven or other
high temperature process.
The PCM can be damaged by: 3. The PCM is designed to process the various inputs
1. Electrostatic discharge and then respond by sending the appropriate
2. The short circuit of some terminals to voltage or to electrical signals to control transmission upshift,
ground. downshift, shift feel and torque converter clutch
engagement.
Electrostatic Discharge Damage Description:
4. The PCM constantly interprets information from the
1. Electronic components used to control systems are various sensors, and controls the systems that affect
often designed to carry very low voltage, and are very transmission and vehicle performance. By analyzing
susceptible to damage caused by electrostatic operational problems, the PCM is able to perform a
discharge. It is possible for less than 100 volts of diagnostic function by displaying DTC(s) and aid the
static electricity to cause damage to some electronic technician in making repairs.
components. By comparison, it takes as much as
4,000 volts for a person to even feel the zap of a static Intermittent Conditions
discharge. If the Tech 2 displays a diagnostic trouble code as
2. There are several ways for a person to become intermittent, or if after a test drive a DTC does not
statically charged. The most common methods of reappear though the detection conditions for this DTC are
charging are by friction and induction. An example of present, the problem is most likely a faulty electrical
charging by friction is a person sliding across a car connection or loose wiring. Terminals and grounds should
seat, in which a charge of as much as 25,000 volts always be the prime suspect. Intermittents rarely occur
can build up. Charging by induction occurs when a inside sophisticated electronic components such as the
person with well insulated shoes stands near a highly PCM.
charged object and momentarily touches ground. Use the DTC information to understand which wires and
Charges for the same polarity are drained off, leaving
sensors are involved.
the person highly charged with the opposite polarity.
When an intermittent problem is encountered, check
Static charges of either type can cause damage,
therefore, it is important to use care when handling suspect circuits for:
and testing electronic components. 1. Poor terminal to wire connection.
2. Terminals not fully seated in the connector body
NOTICE: To prevent possible electrostatic (backed out).
discharge damage:
3. Improperly formed or damaged terminals.
1. Do not touch the PCM connector pins or soldered 4. Loose, dirty, or corroded ground connections:
components on the PCM circuit board.
HINT: Any time you have an intermittent in more than
2. Be sure to follow the guidelines listed below if one circuit, check whether the circuits share a
servicing any of these electronic components: common ground connection.
3. Do not open the replacement part package until it is 5. Pinched or damaged wires.
time to install the part.
6. Electro–Magnetic Interference (EMI):
4. Avoid touching electrical terminals of the part.
HINT: Check that all wires are properly routed away
5. Before removing the part from its package, ground from coil, and generator. Also check for improperly
the package to a known good ground on the vehicle. installed electrical options, such as lights, 2–way
6. Always touch a known good ground before handling radios, etc.
the part. This step should be repeated before Use the F2 SNAPSHOT mode of the Tech 2 to help
installing the part if the part has been handled while isolate the cause of an intermittent fault. The snapshot
sliding across the seat, while sitting down from a mode will record information before and after the problem
standing position or while walking some distance. occurs. Set the snapshot to “trigger” on the suspect DTC.
If you notice the reported symptom during the test drive,
trigger the snapshot manually.
After the snapshot has been triggered, command the
Tech 2 to play back the flow of data recorded from each of
the various sensors. Signs of an intermittent fault in a
sensor circuit are sudden unexplainable jump in data
values out of the normal range.
Transmission And PCM Identification

The chart below contains a list of all important information
concerning rear axle ratio, Powertrain Control Module
(PCM), and transmission identification.
VEHICLE PCM TRANSMISSION
Rr axle
Ratio Calibration
Type Engine ISUZU Parts No. Isuzu Part No. Model Code
Code
Isuzu / 8–09385–189–0
3.5L V6 4.300 G26 8–96018–507–0 YA
Trooper 8–09385–199–0
Isuzu Trooper
240RY004

Identification
DTC MIL “CHECK “CHECK
DTC NAME DTC TYPE
NUMBER ENGINE” TRANS”
P0218 Transmission Fluid Over Temperature D
Transmission Range Switch (Mode Switch) Illegal
P0705 D
Position
Transmission Range Switch (Mode Switch) Perfor-
P0706 D
mance
Transmission Fluid Temperature (TFT) Sensor
P0711 D
Performance
P0712 D
Circuit Low Input
P0713 D
Circuit High Input
P0719 Brake Switch Circuit Low (Stuck ON) D
Automatic Transmission Output Speed Sensor
P0722 B ON Flash
(OSS) Low Input
Automatic Transmission Output Speed Sensor
P0723 B ON Flash
(OSS) Intermittent
P0724 Brake Switch Circuit High (Stuck OFF) D
P0730 Gear Error Without Input Speed C Flash
P0742 Torque Converter Clutch (TCC) System Stuck ON B ON Flash
Pressure Control Solenoid (PCS) (Force Motor)
P0748 C Flash
Circuit Electrical
P0751 Shift Solenoid A Performance (Stuck OFF) B ON Flash
P0752 Shift Solenoid A Performance (Stuck ON) B ON Flash
P0753 Shift Solenoid A Electrical B ON Flash
P0756 Shift Solenoid B Performance (Stuck OFF) B ON Flash
P0757 Shift Solenoid B Performance (Stuck ON) B ON Flash
P0758 Shift Solenoid B Electrical B ON Flash
P1850 Brake Band Apply Solenoid Malfunction D
P1860 TCC Solenoid Electrical B ON Flash
Transmission Component Slipping (TCC Stuck
P1870 B ON Flash
OFF)
DTC TYPE DEFINITION

Emission related, turn on MIL (Check Engine) and flashing Check Trans after 2 consecutive trips
B
(Removal to confirmed)
C Non–emission related, flashing Check Trans on 1st failure
D Non–emission related, no lamps
NOTE: On the following charts, refer to the Powertrain

Control Module (PCM) section for the Wiring System, and
the Body and Accessories section for circuit diagram
details, parts location, and connector configuration.
DTC P0218 Transmission Fluid Over Temperature
D07RY00010

The Transmission Fluid Temperature (TFT) sensor is a D Inspect the wiring for poor electrical connections at
thermister that controls the signal voltage to the PCM. the PCM and at the transmission 16–way connectors.
The PCM supplies a 5–volt reference to the sensor on Look for possible bent, backed out, deformed, or
circuit RED/WHT. When the transmission fluid is cold, the damaged terminals. Check for weak terminal tension
sensor resistance is high and the PCM will sense high as well.
signal voltage. As the fluid temperature warms to a Also check for a chafed wire that could short to bare
normal transmission operating temperature of 100°C metal or other wiring. Inspect for a broken wire inside
(212°F), the sensor resistance becomes less and the the insulation.
voltage decreases to 1.5 to 2.0 volts.
D When diagnosing for a possible intermittent short or
This DTC detects a high transmission temperature for a
open condition, move the wiring harness while
long period of time. This is a type “D” DTC. observing test equipment for a change.
Conditions For Setting The DTC D Check harness routing for a potential short to ground
in circuit RED/WHT.
D No TFT DTCs P0712 or P0713.
D Scan tool TFT sensor temperature should rise
D TFT is greater than 135°C (275°F). steadily to about 100°C (212°F), then stabilize.
D All conditions met for 21 seconds. D Check for a “skewed” (mis–scaled) sensor by
comparing the TFT sensor temperature to the
Action Taken When The DTC Sets ambient temperature after a vehicle cold soak. A
D Hot mode TCC Shift Pattern. “skewed” sensor can cause delayed garage shifts or
D The PCM will not illuminate the Malfunction Indicator TCC complaints.
Lamp (MIL). D Check for a possible torque converter stator problem.
D ATF Lamp ON. (TFT is greater than 145°C (293°F).) D Verify customer driving habits, trailer towing, etc.
D Disable E–side TCC OFF request.
Test Description
Conditions For Clearing The DTC The numbers below refer to the step numbers on the
diagnostic chart.
D The DTC can be cleared from the PCM history by
using a scan tool. 3. This test checks for a “skewed” sensor or shorted
circuit.
D The DTC will be cleared from history when the vehicle
has achieved 40 warm–up cycles without a failure 4. This test simulates a TFT DTC P0713.
reported.
D The PCM will cancel the DTC default actions when
the fault no longer exists and the ignition is cycled “off”
long enough to power down the PCM.
DTC P0218 Transmission Fluid Over Temperature

Step Action Yes No
1 Were you sent here from the “Powertrain On–Board Diagnostic Go to OBD
(OBD) System Check”? System Check
Refer to
Driveability and
Emissions in
Go to Step 2 Engine section
2 Perform the following checks:
D Check for possible engine system problems.
D Transmission fluid checking procedure. Refer to Checking
Transmission Fluid Level and Condition in Automatic
Transmission (4L30–E) Section.
Were the checks performed? Go to Step 3 —
3 1. Install the scan tool.
2. With the engine “off”, turn the ignition switch “on”.
NOTE: Before clearing DTC(s), use the scan tool to record “Failure
Records” for reference, as data will be lost when “Clear Info”
function is used.
3. Record the DTC “Failure Records”.
Go to Diagnostic
Is the TFT sensor signal voltage less than 0.33 volts? Go to Step 4 Aids
4 1. Turn the ignition “off”.
2. Disconnect the transmission 16–way connector H–56
Go to Internal
(additional DTCs may set).
Wiring Harness
Is the TFT sensor signal voltage greater than 4.92 volts? Check. Go to Step 5
5 Inspect/repair circuit RED/WHT for a short to ground.
Was a problem found? Go to Step 7 Go to Step 6
6 1. Inspect the PCM for poor connections.
2. Replace the PCM if no poor connections were found.
Is the replacement complete? Go to Step 7 —
7 1. After the repair is complete, use the scan tool to select “DTC”,
then “Clear Info” function and ensure the following conditions
are met:
TFT is less than 125°C (257°F) for at least 10 seconds.
Begin diagnosis
2. Review the scan tool “DTC Info”. again Repair verified
Has the last test failed or is the current DTC displayed? Go to Step 1 Exit DTC table
DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position
D07RY00011
Circuit Description D The PCM will not illuminate the Malfunction Indicator
Lamp (MIL).
D The range switch supplies the Powertrain Control
Module (PCM) with information regarding the selector
lever position: P, R, N, D 3, 2 or L. The selector lever
Conditions For Clearing The DTC
position is indicated by the state of four ON/OFF D The DTC can be cleared from the PCM history by
contacts. The range switch is located on one side of using a scan tool.
the transmission. It is on the transmission manual D The DTC will be cleared from history when the vehicle
shaft and is fixed to the main case. has achieved 40 warmup cycles without a failure
D The range switch is also used to provide the reported.
information P or N to the engine crank wiring. The D The PCM will cancel the DTC default actions when
engine can be cranked only if connector M–25 the fault no longer exists and the ignition is cycled “off”
terminal 4(H) is connected to terminal 1(E) which is long enough to power down the PCM.
connected to ground.
D The range switch is also used to provide the backup Diagnostic Aids
lamp power in reverse. This is why the range switch is D Refer to accompanying chart for the normal range
supplied through a 15A fuse (C–3). This fuse can signals and the illegal combinations.
burn due to a short circuit in the backup lamp.
D Inspect the wiring for poor electrical connections at
This DTC detects when a fuse is open or the range switch
the PCM and at the transmission 8–way connector.
circuit does not work. This is a type “D” DTC.
Look for possible bent, backed out, deformed or
damaged terminals. Check for weak terminal tension
Conditions For Setting The DTC as well. Also check for a chafed wire that could short
D Range switch illegal positions met for 5 seconds. to bare metal or other wiring. Inspect for a broken wire
inside the insulation.
Action Taken When The DTC Sets D When diagnosing for a possible intermittent short or
D Default to D position. open condition, move the wiring harness while
D Inhibit torque management. observing test equipment for a change.
D Maximum line pressure. D Refer to the “Range Switch Logic Table” or
“Functional Test Procedure” for further information.
D Turn force motor OFF.
Test Description
diagnostic chart:
3. This test checks the indicated range signal to the
manual valve actually selected.
6. This test checks for continuity between each
selected range switch connector terminals.
Range Switch Logic Table
Rangeg Range Switch Pin

Position A B C P(G)
Park ON OFF OFF ON
Reverse ON ON OFF OFF
Neutral OFF ON OFF ON
D4 OFF ON ON OFF
D3 ON ON ON ON
2 ON OFF ON OFF
L OFF OFF ON ON
Illegal OFF OFF OFF OFF
Illegal OFF OFF OFF ON
DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position

Step Action Yes No
Refer to
Driveability and
Emissions in
D The transmission linkage from the select lever to the manual
valve is adjusted properly.
D Diagnostic circuit check.
NOTE: Before clearing DTC(s), use the scan tool to record “Freeze
Frame” and “Failure Records” for reference, as data will be lost
when the “Clear Info” function is used.
3. Record the DTC “Freeze Frame” and “Failure Records”.
4. Select each transmission range: D1, D2, D3, D4, N, R, and P.
Does each selected transmission range match the scan tool Go to Diagnostic
“Range Switch” display? Aids Go to Step 4
4 Are all range switch pin displays incorrect? Go to Step 5 Go to Step 6
5 Check fuse and wiring to the 8–way connector terminal 5(D) for
opens.
Refer to Mode Switch in Automatic Transmission (4L30–E)
section.
If no problem was found, replace the range switch.
6 1. Disconnect the 8–way range switch connector.
2. Using ohmmeter, check continuity between terminal 5(D) and
respectively terminals 3(G), 6(C), 7(B) and 8(A) of the 8–way
range switch connector.
3. Move shift selector lever through all positions and compare
results with “Range Switch Logic Table”.
Is one range switch pin display incorrect? Go to Step 7 Go to Step 8
7 Check the affected wiring and connector, and repair.
Is the repair complete? Go to Step 9 —
8 Check the Powertrain Control Module (PCM) connectors for poor
connection.
If no problem was found, replace the PCM.
then “Clear Info” function and road test the vehicle. Begin diagnosis
DTC P0706 Transmission Range Switch (Mode Switch) Performance
D07RY00011
Circuit Description D Output speed greater than 3,200 RPM.

D The range switch supplies the Powertrain Control D Range switch indicates “R”.
Module (PCM) with information regarding the selector D All conditions met for 4 seconds.
lever position: P, R, N, D, 3, 2 or L. The selector lever
position is indicated by the state of four ON/OFF Condition 2 (“P” or “N” bad position):
contacts. The range switch is located on one side of D Engine is running.
the transmission. It is on the transmission manual
shaft and is fixed to the main case. D No TPS codes.
D The range switch is also used to provide the D Engine speed is less than 3,000 RPM.
information P or N to the engine crank wiring. The D TP angle is greater than 20%.
engine can be cranked only if connector M–25 D Range switch indicates “P” or “N”.
terminal 4(H) is connected to terminal 1(E) which is D All conditions met for 4 seconds.
connected to ground.
D The range switch is also used to provide the backup Action Taken When The DTC Sets
lamp power in reverse. This is why the mode switch is
supplied through a 15A fuse (C–3). This fuse can D Default to “D” position.
burn due to a shot circuit in the backup lamp. D The PCM will not illuminate the Malfunction Indicator
D This DTC detects an invalid state of the range switch Lamp (MIL).
or the range switch circuit by deciphering the range
switch inputs. This is a type “D” DTC. Conditions For Clearing The DTC
Conditions For Setting The DTC using a scan tool.
This DTC will set if any of the following conditions occurs: D The DTC will be cleared from history when the vehicle
has achieved 40 warmup cycles without a failure
Condition 1 (“R” bad position): reported.
D Engine is running. D The PCM will cancel the DTC default actions when
D No output speed DTCP0722, P0723. the fault no longer exists and the ignition is cycled “off”
Diagnostic Aids
D Refer to the accompanying chart for the normal range
signals and the illegal combinations.
the PCM and at the transmission 8–way connector.
Look for possible bent, backed out, deformed or
as well. Also check for a chafed wire that could short
to bare metal or other wiring. Inspect for a broken wire
observing test equipment for a change.
D Refer to the “Range Switch Logic Table” or
“Functional Test Procedure” for further information.
Test Description
diagnostic chart:
manual valve actually selected.
6. This test checks for continuity between each
selected range switch connector terminals.
Range Switch Logic Table
Rangeg Range Switch Pin

Position A B C P(G)
Park ON OFF OFF ON
Neutral OFF ON OFF ON
D4 OFF ON ON OFF
D3 ON ON ON ON
2 ON OFF ON OFF
L OFF OFF ON ON
DTC P0706 Transmission Range Switch (Mode Switch) Performance

Step Action Yes No
Refer to
Driveability and
Emissions in
D The transmission linkage from the select lever to the manual
valve is adjusted properly.
D Diagnostic circuit check.
Does each selected transmission range match the scan tool Go to Diagnostic
“Range Switch” display? Aids Go to Step 4
4 Are all range switch pin displays incorrect? Go to Step 5 Go to Step 6
5 Check fuse and wiring to the 8–way connector terminal 5(D) for
opens.
Refer to Mode Switch in Automatic Transmission (4L30–E)
section.
If no problem was found, replace the range switch.
6 1. Disconnect the 8–way range switch connector.
2. Using ohmmeter, check continuity between terminal 5(D) and
respectively terminals 3(G), 6(C), 7(B) and 8(A) of the 8–way
range switch connector.
3. Move shift selector lever through all positions and compare
results with “Range Switch Logic Table”.
Is one range switch pin display incorrect? Go to Step 7 Go to Step 8
7 Check the affected wiring and connector, and repair.
8 Check the Powertrain Control Module (PCM) connectors for poor
connection.
If no problem was found, replace the PCM.
DTC P0711 Transmission Fluid Temperature (TFT) Sensor Performance
D07RY00010
Circuit Description D If the sensor shows an unrealistic change, the TFT

The TFT sensor is a thermister that controls the signal exhibits a change delta of greater than 20°C (36°F),
greater than 14 times in 7 seconds.
voltage to the PCM. The PCM supplies a 5–volt reference
signal to the sensor on circuit RED/WHT. When the
transmission fluid is cold, the sensor resistance is high
Action Taken When The DTC Sets
and the PCM detects high signal voltage. As the D Transmission default temperature will be:
transmission fluid temperature increases to normal 80°C (176°F) if engine temperature code is set.
operating temperature of 100°C (212°F), the sensor
resistance becomes less and the voltage decreases to 100°C (212°F) if engine temperature is warm.
1.5 to 2 volts. 80°C (176°F) if engine run time is greater than 5
When the PCM detects a TFT sensor that remains at the minutes.
startup value, or a sensor that has a change delta of
21°C (69.8°F) if engine run time is less than 5
greater than 20°C (36°F) less than 1 second, DTC P0711
minutes.
sets. DTC P0711 is a type D.
D The PCM will not illuminate the Malfunction Indicator
Conditions For Setting The DTC Lamp (MIL).
D No VSS DTCs P0722 or P0723.
D No Transmission Component Slipping DTC P1870.
D Engine is running. using a scan tool.
D TFT is between 20 A/D (Analog/Digital) counts and D The DTC will be cleared from history when the vehicle
248 A/D counts. has achieved 40 warmup cycles without a failure
D TFT is between –40°C (–40°F) and +21°C (69.8°F) reported.
at engine startup. D The PCM will cancel the DTC default actions when
D Engine coolant temperature is greater than 70°C the fault no longer exists and the ignition is cycled “off”
(150°F). long enough to power down the PCM.
D Engine coolant temperature has changed by greater
than 50°C (90°F) since engine startup. Diagnostic Aids
D Vehicle speed has been greater than 5 mph for D Inspect the wiring for poor electrical connection at the
greater than 410 seconds since engine startup PCM. Inspect the wiring for poor electrical
(cumulative timer). connections at the transmission 16–way connectors.
D TCC slip speed has been greater than 120 rpm for Look for the following conditions:
greater than 410 seconds since engine startup a. A bent terminal
(cumulative timer). b. A backed out terminal
D Battery voltage is between 10 and 16 volts. c. A damaged terminal
All of the above is true and either of the following occurs: d. Poor terminal tension
D If the sensor is stuck, the TFT has not changed for e. A chafed wire
greater than 2 counts (from startup temperature) for f. A broken wire inside the insulation
greater than 410 seconds.
D When diagnosing for an intermittent short or open Resistance Chart
connection, move the wiring harness while watching
the test equipment for a change. °C °F Resistance (kW)
D First diagnose and clear any engine DTCs or TP –40 –40 672
Sensor codes. Then inspect for any transmission
0 32 65
DTCs that may have reset.
20 68 25
Test Description 80 176 2.5
The number below refers to the step number on the
diagnostic chart: 120 248 0.78
3. This test checks PCM and associated wiring up to 150 304 0.37
the 16–way connectors. If the voltage increases to
match chart the problem is isolated to the
transmission wiring.
DTC P0711 Transmission Fluid Temperature (TFT) Sensor Performance

Step Action Yes No
1 Was the Powertrain On–Board Diagnostic (OBD) System Check Go to OBD
performed? System Check
Refer to
Driveability and
Emissions in
2 Perform the transmission fluid checking procedure. Refer to Go to Checking
Checking Transmission Fluid Level and Condition in Automatic Transmission
Transmission (4L30–E) section. Fluid Level and
Condition in
Did you perform the fluid checking procedure?
Automatic
Transmission
Go to Step 3 (4L30–E) section
2. With the engine “off”, turn the ignition switch to the “on”
position.
NOTE: Before clearing DTCs, use the scan tool in order to record
the Freeze Frame and Failure Records for reference. The Clear
Info function will erase the data.
3. Record the DTC Freeze Frame and Failure Records.
4. Select TFT on the scan tool.
5. While observing the scan tool display, move or massage the
engine wiring harness from PCM connectors J2–66 and J2–20
to the transmission 16–way connectors.
Does the TFT change by more than ±20°C (36°F)? Go to Step 6 Go to Step 4
2. Disconnect the transmission 16–way connector H–56.
3. Install Jumper Harness on the transmission side of the
16–way connector H–56.
4. Using the J39200 DVOM and J35616 Connector Test Adapter
Kit, connect the DVOM leads from terminal M7–4(F) to
terminal M7–1(E).
5. Set the DVOM on MIN/MAX to measure resistance.
6. Record the TFT sensor resistance.
7. Move or massage the automatic transmission wiring harness
assembly from the 16–way connector H–56 to the TFT sensor
connector.
Does the DVOM MAX display a resistance greater than the value
recorded in Action item 6 of this step? Go to Step 7 Go to Step 5
5 Does the DVOM MIN display a resistance less than the value
recorded in Action item 6 of step 4? Go to Step 8 —
DTC P0711 Transmission Fluid Temperature (TFT) Sensor Performance (Cont’d)

Step Action Yes No
6 Inspect circuit RED/WHT and RED/BLK of the engine wiring
harness for an intermittent open or short condition. Repair the
circuits if necessary.
Did you find a problem? Go to Step 12 Go to Step 11
7 Inspect the automatic transmission wiring harness assembly for
an intermittent open in circuits RED/WHT and RED/BLK.
8 Inspect the automatic transmission wiring harness assembly for
an intermittent shorted condition in circuits RED/WHT and
RED/BLK.
9 Replace the automatic transmission wiring harness assembly.
10 Replace TFT Sensor. Refer to Transmission Oil Temperature
Sensor (Main Case) in Automatic Transmission (4L30–E)
section.
11 Replace the PCM. Refer to Powertrain Control Module (PCM) in
Automatic Transmission (4L30–E) section.
12 In order to verify your repair, perform the following procedure.
1. Select DTC.
2. Select Clear Info.
3. Drive the vehicle and ensure the following conditions are met:
D The TFT changes by more than 2.25°C (4.05°F) for 11
seconds since startup.
D The TFT does not change by more than 20°C (36°F) within
0.200 second for a period of at least 11 seconds.
4. Select Specific DTC. Begin the
5. Enter DTC P0711. diagnosis again
Has the test run and passed? System OK Go to Step 1
DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input
D07RY00010
Circuit Description D The DTC will be cleared from history when the vehicle
The TFT sensor is a thermister that controls the signal has achieved 40 warmup cycles without a failure
reported.
signal to the sensor on circuit RED/WHT. When the D The PCM will cancel the DTC default actions when
transmission fluid is cold, the sensor resistance is high. the fault no longer exists and the ignition is cycled “off”
The PCM detects high signal voltage. As the long enough to power down the PCM.
transmission fluid temperature increases to the normal
operating temperature of 100°C (212°F), the sensor Diagnostic Aids
resistance becomes less and the voltage decreases to D Check harness routing for a potential short to ground
1.5 to 2 volts. With transmission fluid over temperature in circuit RED/BLK. Scan tool TFT display should rise
and DTC P0218 also set, check the transmission cooling steadily to about 100°C (212°F), then stabilize.
system. D Inspect the wiring for poor electrical connection at the
This DTC detects a continuous short to ground in the TFT PCM and at the transmission 16–way connectors.
signal circuit or the TFT sensor. This is a type “D” DTC. Look for possible bent, backed out, deformed or
Conditions For Setting The DTC as well. Also check for a chafed wire that could short
D Battery voltage is between 10 and 16 volts. to bare metal or other wiring. Inspect for a broken wire
D Ignition is “on”.
D TFT sensor indicating a voltage less than 0.4 volts. open condition, move the wiring harness while
D All conditions met for 20 seconds. observing test equipment for a change.
D The temperature to resistance value scale may be
Action Taken When The DTC Sets used to test the TFT sensor at the various
D Transmission default temperature will be: temperature levels to evaluate the possibility of a
“skewed” (mis–scaled) sensor.
80°C (176°F) if engine temperature code is set.
A “skewed” sensor could result in delayed garage
100°C (212°F) if engine temperature is warm. shifts or TCC complaints.
80°C (176°F) if engine run time is greater than 5 D Verify customer driving habits, trailer towing, etc.
minutes.
21°C (69.8°F) if engine run time is less than 5 Test Description
minutes. The numbers below refer to the step numbers on the
D The PCM will not illuminate the Malfunction Indicator diagnostic chart:
Lamp (MIL). 3. This test checks for a short to ground or a “skewed”
sensor.
Conditions For Clearing The DTC 4. This test checks for an internal fault within the
D The DTC can be cleared from the PCM history by transmission by creating an open.
using a scan tool.
Resistance Chart
°C °F Resistance (kW)
–40 –40 672
0 32 65
20 68 25
80 176 2.5
120 248 0.78
150 304 0.37
DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input
Step Action Yes No
Refer to
Driveability and
Emissions in
2 Perform the transmission fluid checking procedure. Refer to Refer to
Checking Transmission Fluid Level and Condition in Automatic Checking
Transmission (4L30–E) section. Transmission
Fluid Level and
Was the fluid checking procedure performed?
Condition in
Automatic
Transmission
Does the scan tool display a TFT sensor signal voltage less than Go to Diagnostic
0.4 volts? Go to Step 4 Aids
3. Turn the ignition “on”.
Does the TFT signal voltage change to match the voltage 4.92
volts? Go to Step 5 Go to Step 10
5 Using the J39200 DVOM, measure the resistance between
terminals M7–4(F) and M7–1(E).
Go to Diagnostic
Is the resistance within specifications? (See Resistance Chart.) Aids Go to Step 6
6 1. Disconnect the transmission 7–way connector M–7.
2. Using the J39200 DVOM, measure the resistance between
Go to Diagnostic
7 1. Remove the transmission oil pan. Refer to Transmission Oil
Temperature Sensor (Main Case) in Automatic Transmission
(4L30–E) section.
2. Check the internal wiring harness for a short to ground.
DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input (Cont’d)
Step Action Yes No
8 1. Disconnect the internal wiring harness at the TFT sensor.
2. Measure the resistance of the TFT sensor.
Go to Diagnostic
9 Replace the TFT Sensor.
10 Check circuit RED/WHT for a short to ground.
11 Check the PCM for faulty connections.
are met:
TFT sensor indicates a voltage greater than 0.33 volts for 2
seconds.
Begin diagnosis
2. Review the scan tool “DTC info”. again Repair verified
DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input
D07RY00010
Circuit Description D The DTC will be cleared from history when the vehicle
The TFT sensor is a thermistor that controls the signal has achieved 40 warmup cycles without a failure
reported.
signal to the sensor on circuit RED/WHT. When the D The PCM will cancel the DTC default actions when
transmission fluid is cold, the sensor resistance is high the fault no longer exists and the ignition is cycled “off”
and the PCM will sense high signal voltage. As the long enough to power down the PCM.
transmission fluid temperature warms to the normal
operating temperature of 100°C (212°F), the sensor Diagnostic Aids
resistance becomes less and the voltage decreases to D Inspect the wiring for poor electrical connection at the
about 1.5 to 2 volts. PCM and at the transmission 16–way connectors.
This DTC detects a continuous open or short to power in Look for possible bent, backed out, deformed or
the TFT signal circuit or the TFT sensor. This is a type “D” damaged terminals. Check for weak terminal tension
DTC. as well. Also check for a chafed wire that could short
to bare metal or other wiring. Inspect for a broken wire
Conditions For Setting The DTC inside the insulation.
D Battery voltage is between 10 and 16 volts. D When diagnosing for a possible intermittent short or
D Ignition is “on”. observing test equipment for a change.
D TFT sensor indicating a voltage greater than 4.86 D Scan tool displays transmission fluid temperature in
volts. degrees. After transmission is operating, the
D All conditions met for 20 seconds. temperature should rise steadily to about 100°C
(212°F), then stabilize.
Action Taken When The DTC Sets D The temperature to resistance value scale may be
D Transmission default temperature will be: used to check the TFT sensor at the various
temperature levels to evaluate the possibility of a
80°C (176°F) if engine temperature code is set.
“skewed” (mis–scaled) sensor.
100°C (212°F) if engine temperature is warm. A “skewed” sensor could result in hard shifts or TCC
80°C (176°F) if engine run time is greater than 5 complaints.
minutes.
21°C (69.8°F) if engine run time is less than 5 Test Description
minutes. The numbers below refer to the step numbers on the
diagnostic chart:
Lamp (MIL). 3. This check verifies problem in the TFT sensor circuit.
4. This test simulates a TFT sensor DTC P0712. If the
Conditions For Clearing The DTC PCM recognizes the low signal voltage (high
temperature), and the scan tool displays 146°C
(295°F) or greater, the PCM and wiring are OK.
using a scan tool.
5. This test checks the TFT sensor and internal wiring
harness.
Resistance Chart
°C °F Resistance (kW)
–40 –40 672
0 32 65
20 68 25
80 176 2.5
120 248 0.78
150 304 0.37
DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input
Step Action Yes No
Refer to
Driveability and
Emission in
2 Perform the transmission fluid checking procedure. Refer to
Refer to Checking Transmission Fluid Level and Condition in Checking
Automatic Transmission (4L30–E) section. Transmission
Fluid Level and
Was the fluid checking procedure performed?
Condition in
Automatic
Transmission
Does the scan tool display a TFT sensor signal voltage greater Go to Diagnostic
than 4.86 volts? Go to Step 4 Aids
3. Install a fused jumper wire from terminal M7–4(F) and
M7–1(E) on the engine harness.
Does the TFT signal voltage drop to less than 0.4 volts? Go to Step 5 Go to Step 10
Go to Diagnostic
6 1. Disconnect the transmission 7–way connector M–7.
Go to Diagnostic
DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input (Cont’d)
Step Action Yes No
7 1. Remove the transmission oil pan.
2. Check the internal wiring harness for an open. Refer to
Transmission Oil Temperature Sensor (Main Case) in
Was a problem found and corrected? Go to Step 14 Go to Step 8
8 1. Disconnect the internal wiring harness at the TFT sensor.
2. Measure the resistance of the TFT sensor.
Go to Diagnostic
9 Replace TFT sensor. Refer to Transmission Oil Temperature
Sensor (Main Case) in Automatic Transmission (4L30–E)
section.
10 Check circuit RED/WHT for an open or short to B+.
11 Check circuit RED/BLK for an open.
12 Check the PCM for faulty or intermittent connections.
are met:
2. TFT sensor indicates a voltage less than 4.92 volts for 2
seconds. Begin diagnosis
DTC P0719 Brake Switch Circuit Low (Stuck On)
D07RY00012
Circuit Description: Action Taken When The DTC Sets

The brake switch indicates brake pedal status to the D The PCM does not illuminate the Malfunction
Powertrain Control Module (PCM). The brake switch is a Indicator Lamp (MIL).
normally–closed switch that supplies battery voltage on D DTC P0719 stores in PCM history.
circuit ORN to the PCM. Applying the brake pedal opens
the switch, interrupting voltage to the PCM. When the Conditions For Clearing The DTC
brake pedal is released, the PCM receives a constant
voltage signal. If the PCM receives a zero voltage signal D A scan tool can clear the DTC from the PCM history.
at the brake switch input, and the Torque Converter The PCM clears the DTC from the PCM history if the
vehicle completes 40 warm–up cycles without a
Clutch (TCC) is engaged, the PCM de–energizes the
failure reported.
Torque Converter Clutch Solenoid Valve (TCC Sol.
Valve). The PCM disregards the brake switch input for D The PCM cancels the DTC default actions when the
TCC scheduling if there is a brake switch circuit fault fault no longer exists and the ignition is OFF long
(Refer to Diagnostic Aids). enough in order to power down the PCM.
When the PCM detects an open brake switch circuit (0
volts, low input) during accelerations, then DTC P0719
Diagnostic Aids
sets. DTC P0719 is a type D DTC. D Inspect the wiring for poor electrical connections at
the PCM and brake switch. Look for possible bent,
Conditions For Setting The DTC backed out, deformed or damaged terminals. Check
for weak terminal tension as well. Also check for a
D No OSS Assy. DTCs P0722 or P0723.
chafed wire that could short to bare metal or other
D The PCM detects an open brake switch or circuit (0 wiring. Inspect for a broken wire inside the insulation.
volts) for 15 minutes without changing for 2 seconds,
and the following events occur seven consecutive
times:
D The vehicle speed is less than 8 km/h (5 mph);
D Check customer driving habits and/or unusual driving
D then the vehicle speed is 8–32 km/h (5–20 mph) for conditions (i.e. stop and go, highway).
4 seconds;
D Check brake switch for proper mounting and
D then the vehicle speed is greater than 32 km/h (20 adjustment.
mph) for 4 seconds.
Test Description
diagnostic chart.
3. This step isolates the brake switch as a source for
setting the DTC.
DTC P0719 Brake Switch Circuit Low (Stuck On)

Step Action Yes No
1 Was the Powertrain On–Board Diagnostic (OBD) System Check Go to Powertrain
performed? OBD System
Go to Step 2 Check
2. With the engine “off,” turn the ignition switch to the “on”
position.
NOTE: Before clearing the DTC(s), use the scan tool in order to
record the “Failure Records” for reference. Using the “Clear Info”
function will erase the stored “Failure Records” from the PCM.
3. Record the “DTC Failure Records”, then clear the DTC(s).
4. Select “TCC Brake Switch” on the scan tool.
5. Disconnect the brake switch connector from the brake switch.
6. Connect a test lamp from cavity B13–2 of the brake switch
connector to a known good ground.
Is the test lamp ON? Go to Step 3 Go to Step 4
3 Install a J 36169–A Fused Jumper Wire from terminal B13–3 to
terminal B13–2 of the brake switch connector.
Did the TCC Brake Switch status change from Open to Closed? Go to Step 7 Go to Step 9
4 1. Remove the fuse C–4 (15A).
2. Inspect the fuse for an open.
Is the fuse open? Go to Step 5 Go to Step 8
5 Inspect circuit BLU/WHT for a short to ground condition. Repair
the circuit if necessary.
Did you find a short to ground condition? Go to Step 11 Go to Step 6
6 Inspect circuit ORN for a short to ground condition. Repair the
circuit if necessary.
Did you find a short to ground condition? Go to Step 11 Go to Step 10
7 Replace the brake switch.
8 Inspect circuit BLU/WHT for an open condition. Repair the circuit
if necessary.
Did you find and correct an open condition? Go to Step 11 —
9 Inspect circuit ORN for an open.
Did you find an open condition? Go to Step 11 Go to Step 10
DTC P0719 Brake Switch Circuit Low (Stuck On) (Cont’d)

Step Action Yes No
10 Replace the PCM.
11 In order to verify your repair, perform the following procedure:
1. Select DTC.
2. Select Clear Info.
position.
4. Do not depress the brake pedal.
5. Verify that the TCC Brake Switch status indicates “Closed” (12
volts) for 2 seconds. Begin the
6. Select Specific DTC. Enter DTC P0719. diagnosis again.
DTC P0722 Automatic Transmission Output Speed Sensor (OSS) Low Input
D07RY00016
Circuit Description Conditions For Clearing The MIL/DTC

Output speed information is provided to the PCM by the D The PCM will turn off the MIL and CHECK TRANS
OSS, which is a permanent magnet (PM) generator. The Lamp after three consecutive ignition cycles without a
PM generator produces a pulsing AC voltage. The AC failure reported.
voltage level and number of pulses increases as the D The DTC can be cleared from the PCM history by
speed of the vehicle increases. The PCM then converts using a scan tool. The DTC will be cleared from
the pulsing voltage to output speed, which is used for history when the vehicle has achieved 40 warmup
calculations. The vehicle speed can be displayed with a cycles without a failure reported.
scan tool. D The PCM will cancel the DTC default actions when
This DTC detects a low output speed when there is a high the fault no longer exists and the ignition is cycled “off”
engine speed in a drive gear range. This is a type “B” long enough to power down the PCM.
DTC.
Diagnostic Aids
Conditions For Setting The DTC
D An OSS DTC P0722 will set when no output speed is
D No MAP DTCs P0107 or P0108, P0106, P1106, at detected at start off.
P1107.
D Inspect the wiring for poor electrical connection at the
D No TPS DTCs P0122 or P0123. PCM. Look for possible bent, backed out, deformed
D Not in Park or Neutral. or damaged terminals. Check for weak terminal
D TP angle is greater than 10%. tension as well. Also check for a chafed wire that
could short to bare metal or other wiring. Inspect for a
D Engine vacuum is between 0 and 70kPa.
broken wire inside the insulation.
D Engine speed is between 3,000 and 7,000 rpm.
D Transmission output speed is less than 0 rpm. open condition, move the wiring harness while
D All conditions met for 5 seconds. observing test equipment for a change.
Action Taken When The DTC Sets Test Description

D Fixed to 4th gear. The numbers below refer to the step numbers on the
D Maximum line pressure. diagnostic chart:
D Inhibit TCC engagement. 4. This test checks the OSS circuit.
D For lamp illuminate refer to DTC type definition (type 5. This test checks the integrity of the OSS.
B). 7. This test checks the 5–volt and ground circuit of the
PCM.
DTC P0722 Automatic Transmission Output Speed Sensor (OSS) Low Input
Step Action Yes No
Refer to
Driveability and
Emissions in
4. Raise the drive wheels.
6. Place the transmission in any drive range.
With the drive wheels rotating, does the “Trans Output Speed” Go to Diagnostic
increase with the drive wheel speed? Aids Go to Step 3
3 Check for the most current and/or incorrect calibration.
Is the calibration current? Go to Step 16 Go to Step 4
2. Disconnect the J2 (RED) PCM connector.
harness connector terminals J2–22 and J2–55.
Is the reading 3,000 ohms? Go to Step 5 Go to Step 6
5 1. Select AC volts.
2. Rotate the rear wheels, ensuring the driveshaft is turning.
Is the voltage greater than 0.5 volts? Go to Step 7 Go to Step 8
6 Inspect circuits RED and WHT for a poor connection or an open
circuit.
7 1. Reconnect the J2 (RED) PCM connector.
2. Disconnect the OSS harness from the OSS.
3. With the engine “off”, turn the ignition “on”.
4. Using the J 39200 DVOM, measure the voltage at the OSS
harness connector terminals M15–2 and M15–1.
Is the reading between 4.0 to 5.1 volts? Go to Step 16 Go to Step 10
8 1. Remove the OSS.
2. Check the output shaft speed sensor rotor for damage or
misalignment. Refer to Speed Sensor (Extension Housing) in
9 Replace the OSS.
10 Was the reading in step 7 less than 4.0 volts? Go to Step 12 Go to Step 11
11 Was the reading in Step 7 greater than 5.1 volts? Go to Step 15 —
12 Using the J 39200 DVOM to chassis ground, measure the voltage
on circuit RED.
DTC P0722 Automatic Transmission Output Speed Sensor (OSS) Low Input (Cont’d)
Step Action Yes No
13 Repair the open in circuit WHT.
14 Check circuit RED for a short to ground or open.
15 Repair the short to B+ in circuit RED.
automatic Transmission (4L30–E) section.
then “Clear Info” function and operate the vehicle under the
Transmission output speed is greater than 101 rpm for 3
seconds.
Begin diagnosis
DTC P0723 Automatic Transmission Output Speed Sensor (OSS) Intermittent
D07RY00016
Circuit Description Conditions For Clearing The MIL/DTC

Output speed information is provided to the PCM by the D The PCM will turn off the MIL and CHECK TRANS
OSS, which is a permanent magnet (PM) generator. The Lamp after three consecutive trips without a failure
PM generator produces a pulsing AC voltage. The AC reported.
voltage level and number of pulses increases as the D The DTC can be cleared from the PCM history by
speed of the vehicle increases. The PCM then converts using a scan tool.
the pulsing voltage to output speed, which is used for D The DTC will be cleared from history when the vehicle
calculations. The vehicle speed can be displayed with a has achieved 40 warmup cycles without failure
scan tool. reported.
This DTC detects a low output speed when there is a high
D The PCM will cancel the DTC default actions when
engine speed in a drive gear range. This is a type “B”
the fault no longer exists and the ignition is cycled “off”
DTC. long enough to power down the PCM.
Conditions For Setting The DTC Diagnostic Aids
Drive range
D A OSS DTC P0723 will set when output speed has
D Engine running time is greater than 5 seconds.
been detected and is lost.
D Output speed is greater than 1300 rpm for 2 seconds.
D NORAW-NORAWLAST < 200 rpm for 2 seconds. PCM. Look for possible bent, backed out, deformed
NORAW Latest raw data of output shaft speed. or damaged terminals. Check for weak terminal
tension as well. Also check for a chafed wire that
NORAWLAST Filtered pervious data of output could short to bare metal or other wiring. Inspect for a
speed. broken wire inside the insulation.
D Transmission negative output speed change is D When diagnosing for a possible intermittent short or
greater than 1300 rpm. open condition, move the wiring harness while
D Conditions met for 3 seconds. observing test equipment for a change.
Action During Detection Time Test Description

Output speed value is frozen. The numbers below refer to the step numbers on the
diagnostic chart:
Action Taken When The DTC Sets 4. This test checks the OSS circuit.
D Fixed to 4th gear. 5. This test checks the integrity of the OSS.
D Maximum line pressure. 7. This test checks the 5–volt and ground circuit of the
D Inhibit TCC engagement. PCM.
D For lamp illumination refer to DTC type definition
(type B).
DTC P0723 Automatic Transmission Output Speed Sensor (OSS) Intermittent

Step Action Yes No
Refer to
Driveability and
Emissions in
4. Raise the drive wheels.
6. Place the transmission in any drive range.
With the drive wheels rotating, does the “Trans Output Speed” Go to Diagnostic
increase with the drive wheel speed? Aids Go to Step 3
3 Check for the most current and/or incorrect calibration.
Is the calibration current? Go to Step 16 Go to Step 4
harness connector terminals J2–22 and J2–55.
Is the reading 3,000 ohms? Go to Step 5 Go to Step 6
5 1. Select AC volts.
2. Rotate the rear wheels, ensuring the driveshaft is turning.
Is the voltage greater than 0.5 volts? Go to Step 7 Go to Step 8
6 Inspect circuits RED and WHT for a poor connection or an open
circuit.
7 1. Reconnect the J2 (RED) PCM connector.
2. Disconnect the OSS harness from the OSS.
3. With the engine “off”, turn the ignition “on”.
4. Using the J 39200 DVOM, measure the voltage at the OSS
harness connector terminals M15–2 and M15–1.
8 1. Remove the OSS.
2. Check the output shaft speed sensor rotor for damage or
misalignment. Refer to Speed Sensor (Extension Housing) in
9 Replace the OSS.
10 Was the reading in step 7 less than 4.0 volts? Go to Step 12 Go to Step 11
11 Was the reading in Step 7 greater than 5.1 volts? Go to Step 15 —
12 Using the J 39200 DVOM to chassis ground, measure the voltage
on circuit RED.
DTC P0723 Automatic Transmission Output Speed Sensor (OSS) Intermittent (Cont’d)
Step Action Yes No
13 Repair the open in circuit WHT.
14 Check circuit RED for a short to ground or open.
15 Repair the short to B+ in circuit RED.
Transmission output speed is greater than 101 rpm for 3
seconds.
Begin diagnosis
DTC P0724 Brake Switch Circuit High (Stuck Off)
D07RY00012
Circuit Description: Action Taken When The DTC Sets

The brake switch indicates brake pedal status to the D The PCM does not illuminate the Malfunction
Powertrain Control Module (PCM). The brake switch is a Indicator Lamp (MIL).
normally–closed switch that supplies battery voltage on D DTC P0724 stores in PCM history.
circuit ORN to the PCM. Applying the brake pedal opens
the switch, interrupting voltage to the PCM. When the Conditions For Clearing The DTC
brake pedal is released, the PCM receives a constant
voltage signal. If the PCM receives a zero voltage signal D A scan tool can clear the DTC from the PCM history.
at the brake switch input, and the Torque Converter The PCM clears the DTC from the PCM history if the
vehicle completes 40 warm–up cycles without a
Clutch (TCC) is engaged, the PCM de–energizes the
failure reported.
Torque Converter Clutch Solenoid Valve (TCC Sol.
Valve). The PCM disregards the brake switch input for D The PCM cancels the DTC default actions when the
TCC scheduling if there is a brake switch circuit fault fault no longer exists and the ignition is OFF long
(Refer to Diagnostic Aids). enough in order to power down the PCM.
When the PCM detects a closed brake switch circuit (12
volts, high input) during decelerations, then DTC P0724
Diagnostic Aids
sets. DTC P0724 is a type D DTC. D Inspect the wiring for poor electrical connection at the
PCM. Look for possible bent, backed out, deformed
Conditions For Setting The DTC or damaged terminals. Check for weak terminal
tension as well. Also check for a chafed wire that
D No OSS Assy. DTCs P0722 or P0723.
could short to bare metal or other wiring. Inspect for a
D The PCM detects a closed brake switch circuit (12 broken wire inside the insulation.
volts) without changing and the following events
occur seven consecutive times:
D The vehicle speed is greater than 32 km/h (20 mph) observing test equipment for a change.
for 4 seconds;
D Check customer driving habits and/or unusual traffic
D then the vehicle speed is between 8–32 km/h (5–20 conditions (i.e. stop and go, expressway).
mph) for 4 seconds;
D Check brake switch for proper mounting and
D then the vehicle speed is less than 8 km/h (5 mph). adjustment.
Test Description
diagnostic chart.
2. This step isolates the brake switch as a source for
setting the DTC.
DTC P0724 Brake Switch Circuit High (Stuck Off)

Step Action Yes No
1 Was the Powertrain On–Board Diagnostic (OBD) System Check Go to Powertrain
performed? OBD System
Go to Step 2 Check
position.
NOTE: Before clearing the DTC(s), use the scan tool in order to
record the “Failure Records” for reference. Using the “Clear Info”
function will erase the stored “Failure Records” from the PCM.
3. Record the DTC Failure Records, then clear the DTC(s).
4. Select “TCC Brake Switch” on the scan tool.
5. Disconnect the brake switch connector from the brake switch.
Did the TCC brake switch status change from “Closed” to “Open”? Go to Step 3 Go to Step 4
3 Replace the brake switch.
4 Inspect circuit ORN for a short to B+ condition. Repair the circuit if
necessary.
Did you find a short to B+ condition? Go to Step 6 Go to Step 5
5 Replace the PCM.
6 In order to verify your repair, perform the following procedure:
1. Select DTC.
2. Select “Clear Info”.
3. With the engine “off” turn the ignition switch to the “on” position.
4. Apply the brake pedal.
5. Verify that the TCC brake switch status indicates “Open” (0
volts) for 2 seconds. Begin the
6. Select Specific DTC. Enter DTC P0724. diagnosis again.
DTC P0730 Gear Error Without Input Speed
D07RY00055
Circuit Description D No Transmission Range Switch DTC(s) P0705,

P0706.
D The Powertrain Control Module (PCM) calculates the
slippage of the converter and transmission based D 3 seconds since downshift.
upon the engine speed, the output speed, and the D 3 seconds since garage shift (N→D).
current gear ratio. D And one of the following conditions occur:
D The slippage of the converter at a high enough engine – Slip is greater than 508 rpm in 1st gear.
speed is low. The transmission should not slip more
than a given value when there is no shift. – Slip is greater than 468 rpm in 2nd gear.
D This DTC detects a slip at each gear. This is a type – Slip is greater than 449 rpm on 3rd gear.
“C” DTC.
– Slip is greater than 440 rpm on 4th gear.
Conditions For Setting The DTC D All conditions met for 5.5 seconds.
D No Output Speed Sensor DTC(s) P0722, P0723.
D Not in Park, Neutral, or Reverse.
D Maximum line pressure.
D Engine speed is greater than 3,500 rpm.
D 3 seconds since upshift.
Lamp (MIL).
D The PCM will illuminate the CHECK TRANS Lamp. Diagnostic Aids
D Turn force motor OFF. D Check for intermittent output speed sensor circuit
problems.
Conditions For Clearing The DTC/CHECK D Check for possible incorrect calibration. (PCM part
TRANS Lamp No., tire specification, and rear axle ratio)
D The PCM will turn “off” the CHECK TRANS Lamp
after three consecutive ignition cycles without a Test Description
failure reported. The numbers below refer to the step numbers on the
D The DTC can be cleared from PCM memory by using diagnostic chart:
a scan tool. 3. This step checks for possible low fluid level causing
D The DTC can also be cleared from memory when the slipping resulting in an undefined gear ratio.
vehicle has made 40 warmup cycles without a failure 4. This step checks for correct gear ratios for
reported. commanded gears.
D The PCM will cancel the DTC Actions Taken items 5. This step checks for low line pressure.
when the fault conditions no longer exist and the
ignition is cycles “off” long enough to power down the
PCM.
DTC P0730 Gear Error Without Input Speed

Step Action Yes No
1 Were you sent here from the “On–Board Diagnostic (OBD) Go to OBD
System Check”? System Check
Refer to
Driveability and
Emission in
2 Visually inspect the transmission cooling system for fluid leaks.
D Refer to Chart 16: Possible Causes of Transmission Fluid
Leaks of Mechanical/Hydraulic Diagnosis Symptoms Index in
Automatic Transmission (4L30–E) section
Was condition found and corrected? Go to Step 7 Go to Step 3
3 Refer to Checking Transmission Fluid Level and Condition in Go to Checking
Automatic Transmission (4L30–E) section. Transmission
Fluid Level and
Has transmission fluid checking procedure been performed?
Condition in
Automatic
Transmission
2. Turn the ignition switch to the “on” position.
3. Engine not running.
NOTE: Before clearing DTC(s) use the scan tool to record the
“Failure Records” for reference, as data will be lost when the “Clear
Info” function is used.
4. Record the Failure Record data.
5. Use the scan tool snapshot mode to record transmission gear
ratios.
6. Drive vehicle in transmission gear ranges 1, 2, 3, and D with
the engine speed is greater than 3,500 rpm for 5.5 seconds.
7. Record each transmission gear.
1st:2.73 – 2.99
2nd:1.54 – 1.71
3rd:0.93 – 1.05
4th:0.66 – 0.78
Refer to
Does commanded gear ratio match ranges as shown? Diagnostic Aids Go to Step 5
DTC P0730 Gear Error Without Input Speed (Cont’d)

Step Action Yes No
5 Perform line pressure check.
D Refer to Line Pressure Test in Automatic Transmission
(4L30–E) section.
Was condition found and corrected? Go to Step 7 Go to Step 6
6 Check for possible clutch slippage.
D Refer to Chart 6: Diagnostic Trouble Code (DTC) P0730 of
Mechanical/Hydraulic Diagnosis Symptoms Index in
Was condition found and corrected? Go to Step 7 —
then “Clear info” function.
2. Operate the vehicle under the following conditions:
D Drive the vehicle in D4 with the engine speed greater than
3,500 rpm to obtain anyone of the following gear ratios for
seven seconds.
1st 1:2.73 – 1:2.99
2nd 1:1.54 – 1:1.71
3rd 1:0.93 – 1:1.05
Begin diagnosis
4th 1:0.66 – 1:0.78
again Repair verified
Has the last test failed? Go to Step 1 Exit DTC table
DTC P0742 Torque Converter Clutch (TCC) System Stuck On
D07RY002
Circuit Description D TCC slip speed is between –20 and 40 rpm for 2
The PCM energizes the TCC solenoid by creating an seconds.
ignition voltage on circuit BRN/BLU. When ignition D Vehicle speed is greater than 25 km/h (15 mph) and
voltage is energized by the PCM, the TCC solenoid stops less than 120 km/h (75 mph).
converter signal oil from exhausting. This causes D Speed ratio is greater than 0.9 and less than 2.0.
converter signal oil pressure to increase and move the
TCC valve. The TCC solenoid will deenergize when the Action Taken When The DTC Sets
PCM no longer provides ignition voltage. When the TCC D For lamp illuminate refer to DTC type definition (type
solenoid is deenergized, it will exhaust fluid and release B).
the TCC. D Inhibit TCC engagement.
This DTC detects low torque converter slip when the TCC
is commanded “off”. This is a type “B” DTC. Conditions For Clearing The MIL/DTC
Conditions For Setting The DTC D The PCM will turn off the MIL and CHECK TRANS
The following conditions occur once per TCC cycle, three Lamp after three consecutive ignition cycles without a
failure reported.
consecutive times:
D No TPS DTCs P0122 or P0123. D The DTC can be cleared from the PCM history by
using a scan tool.
D No OSS DTCs P0722 or P0723.
D The DTC will be cleared from history when the vehicle
D No TCC solenoid DTC P1860. has achieved 40 warmup cycles without a failure
D TP angle is greater than 20%. reported.
D Engine speed is greater than 500 rpm and less than D The PCM will cancel the DTC default actions when
3,000 rpm. the fault no longer exists and the ignition is cycled “off”
D Engine vacuum is between 0 and 70 kPa. long enough to power down the PCM.
D Commanded gear is not 1st.
D Gear range is D4.
D TCC is commanded “off”.
D No TCC Stuck off DTC P1870.
Diagnostic Aids Test Description

D If the TCC is mechanically stuck “on” with the parking The number below refers to the step number on the
brake applied and any gear range selected, the TCC diagnostic chart:
fluid will mechanically apply the TCC, possibly 3. This test checks the mechanical state of the TCC.
causing an engine stall. (When the PCM commands the TCC solenoid “off”,
the slip speed should increase).
DTC P0742 Torque Converter Clutch (TCC) System Stuck On

Step Action Yes No
Refer to
Driveability and
Emissions in
4. Using the scan tool, verify the “TP Sensor” operation.
Go to Diagnostic
Are the “TP Sensor” values within 0.6 – 5.0 volts? Go to Step 3 Aids
3 Drive the vehicle in the D4 drive range in fourth gear under steady
acceleration, with a TP angle greater than 20%.
Does the scan tool display “TCC Slip Speed” between –30 and Go to Diagnostic
+30 rpm, while the displayed TCC solenoid state is “off”? Go to Step 4 Aids
4 The TCC is mechanically stuck “on”. Check the following items:
D Clogged exhaust orifice in the TCC solenoid.
D Converter clutch apply valve stuck in the apply position.
D Misaligned or damaged valve body gasket.
D Restricted release passage.
Was a problem found and corrected? Go to Step 5 —
are met:
TCC slip speed must be between 200 and 2,500 rpm for 4
seconds.
Begin diagnosis
DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical
D07RY00013
Circuit Description D The DTC can be cleared from PCM history by using a
The PCS is a PCM–controlled device used to regulate scan tool.
transmission line pressure. The PCM compares TPS D The DTC will be cleared from memory when the
voltage, engine rpm, and other inputs to determine the vehicle has achieved 40 warmup cycles without a
line pressure appropriate for a given load. The PCM will failure reported.
regulate the pressure by applying a varying amperage to D The PCM will cancel the DTC default actions when
the PCS. The applied amperage can vary from 0.1 to 1 the fault no longer exists and the ignition is cycled “off”
amp, and is monitored by the PCM. long enough to power down the PCM.
This DTC detects a continuous open or short to ground in
the PCS circuit or the PCS. This is a type “C” DTC. Diagnostic Aids
Conditions For Setting The DTC PCM and at the transmission 4–way connector. Look
D Battery voltage is between 10 and 16 volts. for possible bent, backed out, deformed or damaged
terminals. Check for weak terminal tension as well.
D The PCM detects that the different between
Also check for a chafed wire that could short to bare
commanded and actual current is 200 milliampere
metal or other wiring. Inspect for a broken wire inside
(mA) for over 1 second.
the insulation.
D Engine speed is greater than 300 rpm.
Action Taken When the DTC Sets observing test equipment for a change.
Lamp (MIL). Test Description
D Maximum line pressure. The numbers below refer to the step numbers on the
D The PCM will illuminate the CHECK TRANS Lamp. diagnostic chart:
D Turn force motor OFF (Durability). 2. This test checks the ability of the PCM to command
the PCS.
Conditions For Clearing The DTC/CHECK 3. This test checks the PCS and internal wiring harness
TRANS Lamp for incorrect resistance.
D The PCM will turn “off” the CHECK TRANS Lamp
after three consecutive ignition cycles without a
failure reported.
DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical
Step Action Yes No
Refer to
Driveability and
Emission in
NOTE: Before clearing DTC(s), use the scan tool to record “Failure
Records” for reference, as data will be lost when the “Clear Info”
function is used.
3. Record the DTC “Failure Records”.
4. While the engine is operating, put the transmission in Park.
5. Using the scan tool, apply 0.1 amp through 1.0 amp while
observing “PC Ref. Current” and “PC Act. Current”.
Go to Diagnostic
Is the “PC Act. Current” reading always within 0.16 amp? Aids Go to Step 3
2. Disconnect the transmission 4–way connector M–6.
terminals M6–2(B) and M6–4(C).
Is the resistance within 3–7 ohms? Go to Step 7 Go to Step 4
4 1. Remove the transmission oil pan. Refer to Solenoid (Adapter
Case Valve Body) in Automatic Transmission (4L30–E)
section.
2. Disconnect the internal wiring harness at the PCS.
3. Measure the resistance of the PCS.
5 Replace the PCS.
6 Repair the internal wiring harness for an open.
7 Inspect/repair circuits J1–47, M6–2(B), J1–43, and M6–4(C).
8 Inspect/repair circuits J1–47, M6–2(B), J1–43, and M6–4(C) for a
short to ground or poor connections.
are met:
The PCS duty cycle is not at its electrical high or low limit.
Begin diagnosis
DTC P0751 Shift Solenoid A Performance (Stuck OFF)
D07RT011
Circuit Description Condition 2:

The shift solenoid A is used to control fluid flow acting on D 3rd Gear is commanded for ≥ 1 sec.
the 1–2 and 3–4 shift valves. The solenoid is a normally D 40 ≤ Engine Torque ≤ 400 N·m
close exhaust valve that is used with the shift solenoid B
D Trottle position ≥ 10%
to allow four different shifting combinations.
The DTC detects when there is only a 1–1–4–4 shift D –8000 ≤ TCC slip ≤ 8000 rpm
pattern depending on the state of the mechanical failure D Speed ratio ≥ 0.45
instead of a 1–2–3–4 shift pattern. This is a type “B” DTC. D 0.62 ≤ Modeled Ratio ≤ 0.92 for 3 seconds
Conditions For Setting The DTC Action Taken When the DTC Sets
D No ETC DTCs. D Maximum line pressure.
D No OSS DTCs P0722 or P0723. D For lamp illuminate refer to DTC type definition (type
D No TCC solenoid DTC P0742, P1860, P1870. B).
D No shift solenoid A DTC P0753. D Turn force motor OFF.
D No shift solenoid B DTC P0758.
D Gear range is D4.
Conditions For Clearing The The MIL/DTC
D Output speed is greater than 375 rpm. D The PCM will turn off the MIL and CHECK TRANS
Lamp after three consecutive ignition cycles without a
D Transmission temperature is between 20° and 130°C failure reported.
(68° and 266°F).
D No range code P0705, P0706. using a scan tool.
D No torque code (to be confirmed). D The DTC will be cleared from history when the vehicle
D Engine run for more 0 seconds and not influed cut-off has achieved 40 warmup cycles without a failure
(to be confirmed). reported.
All the above conditions have been met and the D The PCM will cancel the DTC default actions when
combination of conditions 1, 2 occur two consecutive the fault no longer exists and the ignition is cycled “off”
times. long enough to power down the PCM.
Condition 1: Diagnostic Aids
D 2nd gear is commanded for ≥ 1 sec D Verify that the transmission meets the specifications
D 40 ≤ Engine Torque ≤ 400 N·m in the 4L30–E shift speed chart.
D Throttle positon ≥ 10% D Other internal transmission failures may allow more
D 800 ≤ TCC slip ≤ 4000 rpm than one shift to occur.
D Speed ratio ≥ 0.6
D 2.75 ≤ Modeled Ratio ≤ 3.2 for 1 seconds.
Test Description
diagnostic chart:
2. This test checks the function of the range switch
(mode switch).
3. This test checks that the scan tool commanded all
shifts, all shifts solenoids responded correctly, but
all the shifts did not occur.
DTC P0751 Shift Solenoid A Performance (Stuck OFF)

Step Action Yes No
Refer to
Driveability and
Emissions in
4. With the engine operating, apply the brake pedal and select
each transmission range D1, D2, D3, D4, N, R, and P.
Go to“Range
Does each selected transmission range match the “TR Switch” on Switch Logic
the scan tool? Go to Step 3 Table”
3 1. While the engine is operating, raise the drive wheels.
2. With the transmission in D4 range, use the scan tool to
command 1st, 2nd and 3rd, and 4th gears while accelerating
the vehicle.
Was a 2–3 or 1–4 only shift pattern detected? (Road testing the Go to Diagnostic
vehicle may be necessary). Go to Step 4 Aids
4 Check the shift solenoid/hydraulic circuit for:
D One or both of the shift solenoids for an internal malfunction.
D Contamination or sediment in one or both of the shift
solenoids.
D Damaged seals on one or both of the shift solenoids.
Refer to Solenoid (Main Case Valve Body) in Automatic
Transmission (4L30–E) section.
Go to Diagnostic
Was a problem found and corrected? Go to Step 5 Aids
DTC P0752 Shift Solenoid A Performance (Stuck ON)
D07RT011

The shift solenoid A is used to control fluid flow acting on D 4th Gear is commanded for ≥ 1 sec.
the 1–2 and 3–4 shift valves. The solenoid is a normally D 40 ≤ Engine Torque ≤ 400 N·m
close exhaust valve that is used with the shift solenoid B
to allow four different shifting combinations.
The DTC detects when there is only a 2–2–3–3 shift D –8000 ≤ TCC slip ≤ 8000 rpm
D Gear range is D4.
Conditions For Clearing The The MIL/DTC
D Transmission temperature is between 20° and 130°C failure reported.
(68° and 266°F).
combination of condition 1, 2 occur two consecutive the fault no longer exists and the ignition is cycled “off”
D 1st gear is commanded for ≥ 1 sec D Verify that the transmission meets the specifications
D 40 ≤ Engine Torque ≤ 400 N·m in the 4L30–E shift speed chart.
D Throttle positon ≥ 10% D Other internal transmission failures may cause more
D –8000 ≤ TCC slip ≤ 8000 rpm than one shift to occur.
D Transmission out speed ≥ 375 rpm
D 1.5 ≤ Modeled Ratio ≤ 2.4 for 0.687 seconds
Test Description
diagnostic chart:
(mode switch).
3. This test checks that the scan tool commanded all
shifts, all shifts solenoids responded correctly, but
all the shifts did not occur.
DTC P0752 Shift Solenoid A Performance (Stuck ON)

Step Action Yes No
Refer to
Driveability and
Emissions in
Go to“Range
command 1st, 2nd and 3rd, and 4th gears while accelerating
the vehicle.
Was a 2–3 or 1–4 only shift pattern detected? (Road testing the Go to Diagnostic
vehicle may be necessary). Go to Step 4 Aids
solenoids.
D Damaged seals on one or both of the shift solenoids.
Go to Diagnostic
DTC P0753 Shift Solenoid A Electrical
D07RY00014
Circuit Description Action Taken When The DTC Sets

D The shift solenoid A is a simple on/off solenoid D Maximum line pressure.
located in the main case valve body. The solenoid is D Immediate landing to 4th gear.
the normally closed type. In second or third gear, the
D Inhibit TCC engagement.
Powertrain Control Module (PCM) energizes the
solenoid to open a fluid inlet port. When the port is D For lamp illuminate refer to DTC type definition (type
open, fluid pressure actuates the shift valve. B).
D The solenoid is activated by current. This current is
produced by applying a voltage to one side (the High Conditions For Clearing The MIL/DTC
side) and a ground to the other side (Low side). D The PCM will turn off the MIL and CHECK TRANS
D The High Side Driver (HSD) is a circuit of the PCM Lamp after three consecutive ignition cycles without a
that acts as a switch between the solenoids and the failure reported.
supply voltage. The High side of the solenoid is D The DTC can be cleared from the PCM history by
permanently supplied with voltage, except in using a scan tool.
BACKUP MODE or when ignition is off the HSD is D The DTC will be cleared from history when the vehicle
turned off. has achieved 40 warmup cycles without a failure
This DTC detects a continuous open or short to ground in reported.
the shift solenoid A circuit or the shift solenoid A. This is a D The PCM will cancel the DTC default actions when
type “B” DTC. the fault no longer exists and the ignition is cycled “off”
D Ignition is “on”, Engine “run”. Diagnostic Aids
D Battery voltage is between 10 and 16 volts. D Inspect the wiring for poor electrical connection at the
D The PCM commands the solenoid “on” and the PCM and at the transmission 16–way connectors.
voltage remains high (B+) or the PCM commands the Look for possible bent, backed out, deformed or
solenoid “off” and the voltage remains low (zero damaged terminals. Check for weak terminal tension
volts). as well. Also check for a chafed wire that could short
D All conditions met for 0.84 ∼ 1.0 seconds. to bare metal or other wiring. Inspect for a broken wire
D When diagnosing for a possible intermittent short or 5. This test measures the resistance of the component.
open condition, move the wiring harness while 9. This test checks the function of the shift solenoid A
observing test equipment for a change. and the transmission internal wiring harness.
D An open ignition feed circuit can cause multiple DTCs Shift Solenoid Status Chart
to set.
D A shift solenoid B DTC P0758 could also set with a Gear Shift solenoid A Shift solenoid B
shift solenoid A electrical failure. 1st OFF ON
Test Description 2nd ON ON
The numbers below refer to the step numbers on the 3rd ON OFF
diagnostic chart:
4th OFF OFF
3. This test checks for power to the shift solenoid A
from the ignition through the PCM.
DTC P0753 Shift Solenoid A Electrical

Step Action Yes No
Refer to
Driveability and
Emissions in
2. With the engine “on”, turn the ignition switch “on”.
Go to Diagnostic
Were DTCs P0753, P0758, P1860 set? Go to Step 3 Aids
3 1. Turn the ignition “on”.
2. Using the J39200 DVOM, measure the voltage between PCM
connector terminals J2–43 and J1–1 (GND).
Is the voltage within 10–12 volts? Go to Step 4 Go to Step 5
connector terminals J1–5 and ground.
Is the voltage within 10 – 12 volts? Go to Step 11 Go to Step 5
PCM connector terminals J2–43 and J1–5.
Is the resistance within 18 – 20 ohms? Go to Step 6 Go to Step 7
6 1. Disconnect the J1 (BLUE) and J2 (RED) PCM connectors.
2. Using the J39200 DVOM, check a continuity between PCM
terminals J2–43 and ground.
Is there a continuity? Go to Step 12 Go to Step 8
7 1. Disconnect the 16–way harness connector H–56.
terminals H56–11 and H56–10.
DTC P0753 Shift Solenoid A Electrical (Cont’d)

Step Action Yes No
8 Using the J39200 DVOM, check a continuity between J2 (RED)
PCM terminal 43 and ground.
9 1. Disconnect the transmission main case 7 pin connector M–7.
terminals M7–2(D) and M7–3(C).
10 Check every connection at the PCM connector.
11 The wiring harness between PCM connector terminals J1–5 and
transmission harness terminal M7–3(C) is shorted to voltage.
12 The wiring harness between PCM connector terminal
J1–5 and transmission harness terminal M7–3(C) is shorted to
ground.
13 The wiring harness between PCM connector terminals J2–43 and
transmission harness terminal M7–2(D) is shorted to ground.
14 The wiring harness between PCM connector J1 or J2 and
transmission 16–way connector H–56 is open or poor connection.
15 The wiring harness between transmission 16–way connector
H–56 and transmission main case connector M–7 is open or has a
poor connection.
16 The shift solenoid A is faulty.
Replace the shift solenoid A. Refer to Solenoid (Main Case Valve
Body) in Automatic Transmission (4L30–E) section.
17 The PCM may be faulty.
Replace the PCM. Refer to Powertrain Control Module (PCM) in
18 Repair the PCM connector connection.
D The shift solenoid A is commanded “on” and voltage drops to
zero.
D The shift solenoid A is commanded “off” and voltage
increases to B+. Begin diagnosis
DTC P0756 Shift Solenoid B Performance (Stuck OFF)
D07RT011

The shift solenoid B is used to control fluid flow acting on D 2nd Gear is commanded for ≥ 1 sec.
the 2–3 shift valves. The solenoid is a normally open D 40 ≤ Engine Torque ≤ 400 N·m
exhaust valve that is used with the shift solenoid A to allow
four different shift combinations.
This DTC detects when there is only a 4–3–3–4 shift D –8000 ≤ TCC slip ≤ 8000 rpm
instead of a 1–2–3–4 shift pattren. This is a type “B” DTC. D 0.92 ≤ Modeled Ratio ≤ 1.5 for 0.687 seconds
D No TCC solenoid DTC P0742, P1860., P1870. B).
D Gear range is D4.
Conditions For Clearing The MIL/DTC
D Transmission fluid temperature is between 20° and failure reported.
130°C (68° and 266°F).
D Engine run for more 0 seconds and influed cut-off (to has achieved 40 warmup cycles without a failure
be confirmed). reported.
combination of condition 1, 2 occur two consecutive the fault no longer exist and the ignition is cycled “off”
D 1st gear is commanded for ≥ 1 sec D Verify that the transmission meets the specifications
D 40 ≤ Engine Torque ≤ 400 N·m in the 4L30-E shift speed chart.
D Throttle position ≥ 10% D Other internal transmission failures may allow more
D 0.60 ≤ Modeled Ratio ≤ 1.49 for 1 seconds
Test Description
diagnostic chart:
(mode switch).
3. This test checks for selected gear ratio vs. a ratio
not obtainable under normal driving conditions.
DTC P0756 Shift Solenoid B Performance (Stuck OFF)

Step Action Yes No
Refer to
Driveability and
Emissions in
Go to “Range
command 1st, 2nd, and 3rd, and 4th gears while accelerating
the vehicle.
Was 1st gear commanded and not achieved, or 4th gear
commanded and other than 4th gear occurred? (Road testing the Go to Diagnostic
vehicle may be necessary.) Go to Step 4 Aids
solenoids.
D Damaged seals on the one or both of the shift solenoids.
Go to Diagnostic
DTC P0757 Shift Solenoid B Performance (Stuck ON)
D07RT011

The shift solenoid B is used to control fluid flow acting on D 4th Gear is commanded for ≥ 1 sec.
the 2–3 shift valves. The solenoid is a normally open D 15 ≤ Engine Torque ≤ 400 N·m
exhaust valve that is used with the shift solenoid A to allow
four different shift combinations.
This DTC detects when there is only a 1–2–2–1 shift D –8000 ≤ TCC slip ≤ 8000 rpm
D Gear range is D4.
D Transmission fluid temperature is between 20° and failure reported.
130°C (68° and 266°F).
combination of condition 1,2 occur two consecutive the fault no longer exists and the ignition is cycled “off”
D 3rd gear is commanded for ≥ 1 sec D Verify that the transmission meets the specifications
D 40 ≤ Engine Torque ≤ 400 N·m in the 4L30-E shift speed chart.
D Throttle positon ≥ 10% D Other internal transmission failures may cause more
D 1.44 ≤ Modeled Ratio ≤ 2.4 for 4 seconds
Test Description
diagnostic chart:
(mode switch).
3. This test checks for selected gear ratio vs. a ratio
not obtainable under normal driving conditions.
DTC P0757 Shift Solenoid B Performance (Stuck ON)

Step Action Yes No
Refer to
Driveability and
Emissions in
Go to “Range
command 1st, 2nd, and 3rd, and 4th gears while accelerating
the vehicle.
Was 1st gear commanded and not achieved, or 4th gear
commanded and other than 4th gear occurred? (Road testing the Go to Diagnostic
vehicle may be necessary.) Go to Step 4 Aids
solenoids.
D Damaged seals on the one or both of the shift solenoids.
Go to Diagnostic
DTC P0758 Shift Solenoid B Electrical
D07RY00014
Circuit Description Action Taken When The DTC Sets

D The shift solenoid B is a simple on/off solenoid D Fixed to 4th gear.
located in the main case valve body. It is normally D Maximum line pressure.
open. When the port is open, fluid pressure actuates
D Inhibit TCC engagement.
the shift valve. In first or second gear, the Powertrain
Control Module (PCM) energizes the solenoid to D The PCM will illuminate the Malfunction Indicator
close a fluid inlet port. Lamp (MIL) and CHECK TRANS Lamp.
D The solenoid is activated by current. This current is
produced by applying a voltage to one side (the High Conditions For Clearing The MIL/DTC
side) and a ground to the other side (Low side). D The PCM will turn off the MIL and CHECK TRANS
D The High Side Driver (HSD) is a circuit of the PCM Lamp after three consecutive ignition cycles without a
that acts as a switch between the solenoids and the failure reported.
supply voltage. The High side of the solenoid is D The DTC can be cleared from the PCM history by
permanently supplied with voltage. In BACKUP using a scan tool.
MODE or when the ignition is off, the HSD is turned D The DTC will be cleared from history when the vehicle
off. has achieved 40 warmup cycles without a failure
This DTC detects a continuous open or short to ground in reported.
the shift solenoid B circuit or shift solenoid B. This is a D The PCM will cancel the DTC default actions when
type “B” DTC. the fault no longer exists and the ignition is cycled “off”
D Ignition is “on”, Engine “run”. Diagnostic Aids
D Battery voltage is between 10 and 16 volts. D Inspect the wiring for poor electrical connections at
D The PCM commands the solenoid “on” and the the PCM and at the transmission 16–way connector.
voltage remains high (B+)or the PCM commands the Look for possible bent, backed out, deformed or
solenoid “off” and the voltage remains low (zero damaged terminals. Check for weak terminal tension
volts). as well. Also check for a chafed wire that could short
D All conditions met for 0.84 ∼ 1.0 seconds. to bare metal or other wiring. Inspect for a broken wire
D When diagnosing for a possible intermittent short or Shift Solenoid Status Chart
observing test equipment for a change. Gear Shift solenoid A Shift solenoid B
1st OFF ON
Test Description
2nd ON ON
diagnostic chart: 3rd ON OFF
5. This test measures the resistance of the component. 4th OFF OFF
7. This test checks the function of the shift solenoid B
and the transmission internal wiring harness.
11.This test checks for power to the shift solenoid B
from the ignition through the PCM.
DTC P0758 Shift Solenoid B Electrical

Step Action Yes No
Refer to
Driveability and
Emissions in
Were DTCs P0753, P0758, P1860 set? Go to Step 4 Go to Step 3
3 1. The engine “on”.
2. Apply brake pedal and select transmission range “D”.
3. Press and hold down the winter switch and select transmission
mode “winter”.
Go to Diagnostic
Does the scan tool display DTC P0758 at 3rd gear? Go to Step 8 Aids
2. Disconnect the J1 (BLUE) and J2 (RED) PCM connectors.
connector terminals J2–31 and J1–1.
Is the voltage within 10 – 12 volts? Go to Step 15 Go to Step 5
6 1. Disconnect the transmission 16–way connector H–56.
7 1. Disconnect the transmission main case connector M–7.
terminals M7–2(D) and M7–6(A).
DTC P0758 Shift Solenoid B Electrical (Cont’d)

Step Action Yes No
9 Using the J39200 DVOM, check a continuity between PCM
connector terminal J2–31 and ground.
11 Using the J39200 DVOM, check a continuity between PCM
connector terminal J2–43 and ground.
terminals M7–2(D) and M7–6(A).
13 Check every connection of the PCM and transmission 16–way
connector H–56.
14 1. Connect the J1 (BLUE) and J2 (RED) PCM connectors to the
PCM.
2. Turn the ignition “on”, the engine “on”.
3. Repeat Step 3.
Go to Diagnostic
Does the scan tool display DTC P0758 at 3rd gear? Go to Step 25 Aids
J2–31 and transmission main case terminal M7–6(A) is shorted to
voltage.
16 The PCM internal terminal J2–31 is shorted to voltage.
Replace the PCM. Refer to Powertrain Control Module (PCM) in
17 The wiring harness between PCM connector and transmission
16–way connector is shorted.
18 The wiring harness between transmission 16–way connector and
transmission main case connector is shorted.
19 The shift solenoid B is faulty, or the internal wiring harness from
the shift solenoid B is shorted.
J2–31 and transmission main case connector terminal M7–6(A) is
shorted to ground.
DTC P0758 Shift Solenoid B Electrical (Cont’d)

Step Action Yes No
21 The wiring harness between PCM connector terminal J2–31 and
transmission 16–way connector terminal H56–12, or between
PCM connector terminal J2–43 and 16–way connector terminal
H56–11 is open.
transmission main case connector terminal M7–2(D) is shorted to
ground.
terminal H56–12 and transmission main case connector terminal
M7–6(A), or between H56–11 and M7–2(D) is open.
24 The internal wiring harness from the shift solenoid B is open, or
the shift solenoid B is faulty.
25 Replace the PCM.
D The shift solenoid B is commanded “on” and voltage drop to
zero.
D The shift solenoid B is commanded “off” and voltage
increases to B+. Begin diagnosis
DTC P1850 Brake Band Apply Solenoid Malfunction
D07RY00014
Circuit Description Conditions For Setting The DTC

D The brake band apply solenoid is a normally open D Battery voltage is between 10 and 16 volts.
solenoid which controls the flow of fluid for brake band D Ignition is “on”, Engine “run”.
application. The Powertrain Control Module (PCM)
D The PCM commands the solenoid “on” and the
uses Pulse Width Modulation (PWM) and changes
voltage remains high (B+) or the PCM commands the
the duty cycle to control the solenoid. The PCM turns
solenoid “off” and the voltage remains low (zero
the solenoid on (energized) and off (deenergized) at a
volts).
constant frequency. The length of time the solenoid is
energized during each on/off cycle is called the pulse D All conditions met in 1.34 ∼ 1.56 seconds.
width. By varying or “modulating” the pulse width, the
solenoid output pressure is changed. Since the Action Taken When The DTC Sets
solenoid is normally open, increasing the pulse width D Inhibit brake band apply solenoid.
increases the duty cycle and decreases the output
pressure. PWM control provides smooth band
Lamp (MIL).
application without an accumulator. The band is only
applied in first and second gears.
D In the event of an electrical failure (open), the
solenoid regulates at the maximum oil flow (0% duty D The DTC can be cleared from the PCM history by
cycle). using a scan tool.
D The solenoid is activated by current. This current is D The DTC will be cleared from history when the vehicle
produced by applying a voltage to one side (the High has achieved 40 warmup cycles without a failure
side) and a ground to the other side (Low side). reported.
D The High Side Driver (HSD) is a circuit of the PCM D The PCM will cancel the DTC default actions when
that acts as a switch between the solenoids and the the fault no longer exists and the ignition is cycled “off”
supply voltage. The High side of the solenoid is long enough to power down the PCM.
permanently supplied with voltage. When the ignition
is off, the HSD is turned off.
This DTC detects a continuous open or short to ground in
the brake band apply solenoid circuit or the brake band
apply solenoid. This is a type “D” DTC.
Diagnostic Aids Test Description

D Inspect the wiring for poor electrical connection at the The numbers below refer to the step numbers on the
PCM and at the transmission 16–way connectors. diagnostic chart:
Look for possible bent, backed out, deformed or 3. This test checks for power to the brake band apply
damaged terminals. Check for weak terminal tension solenoid from the ignition through the PCM.
as well. Also check for a chafed wire that could short 4. This test checks the resistance of the transmission
to bare metal or other wiring. Inspect for a broken wire internal wiring harness and brake band apply
inside the insulation. solenoid.
D When diagnosing for a possible intermittent short or 5. This test checks the ability of the PCM and wiring to
open condition, move the wiring harness while control the ground circuit.
DTC P1850 Brake Band Apply Solenoid Malfunction

Step Action Yes No
Refer to
Driveability and
Emissions in
Were DTCs P0753, P0758 set? Go to Step 3 Go to Step 4
3 Using the J39200 DVOM, back probe between PCM connector
terminals J2–43 and J1–1.
Is the voltage between 10 to 12 volts? Go to Step 5 Go to Step 6
Is the voltage between 10 to 12 volts? Go to Step 26 Go to Step 4
3. Using the J39200 DVOM, check continuity between PCM
terminal J2–43 and ground.
2. Using the J39200 DVOM, check continuity between connector
H56–9 and ground.
2. Using the J39200 DVOM, check continuity between the
terminal M7–7(B) and ground.
DTC P1850 Brake Band Apply Solenoid Malfunction (Cont’d)

Step Action Yes No
9 1. Disconnect the J1 (BLUE) and J2 (RED) PCM Connector.
terminal H56–11 and H56–9.
terminals M7–2(D) and M7–7(B).
12 Using the J39200 DVOM, check continuity between PCM
terminal J2–10 and ground.
terminal H56–11 and H56–9.
2. Using the J39200 DVOM, check continuity between terminal
H56–9 and ground.
terminals M7–2(D) and M7–7(B).
2. Using the J39200 DVOM, check continuity between the
terminal M7–7(B) and ground.
17 The wiring harness between PCM terminal J2–43 and
transmission 16–way connector terminal H56–11 is open.
18 The brake band apply solenoid is faulty, or the internal wiring
harness from the brake band apply solenoid is shorted to ground.
19 The wiring harness between the transmission 16–way connector
terminal H56–11 and the transmission main case connector
terminal M7–2(D) is shorted to ground.
terminal M7–2(D) is open.
21 The brake band apply solenoid is faulty, or the internal wiring
harness from the brake band apply solenoid is open.
DTC P1850 Brake Band Apply Solenoid Malfunction (Cont’d)

Step Action Yes No
22 The wiring harness between the PCM connector terminal J2–10
and transmission 16–way connector terminal H56–9 is shorted to
ground.
terminal M7–7(B) is shorted to ground.
24 The wiring harness between the PCM connector terminal J2–10
and the 16–way connector terminal H56–9 is open.
terminal M7–7(B) is open.
26 Check every connection at the PCM.
If OK, replace the PCM. Refer to Powertrain Control Module
(PCM) in Automatic Transmission (4L30–E) section.
are met:
D The brake band apply solenoid is commanded “on” and the
volts drop to zero.
D The brake band apply solenoid is commanded “off” and the
volts increase to B+. Begin diagnosis
DTC P1860 TCC PWM Solenoid Electrical
D07RY00015
Circuit Description D For lamp illuminate refer to DTC type definition (type
The PCM allows current to flow through the solenoid coil B).
according to the duty cycle (percentage of “on” and “off”
time). This current flow through the solenoid coil creates
a magnetic field that magnetizes the solid core. The D The PCM will turn off the MIL and CHECK TRANS
magnetized core attracts the check ball to seat against Lamp after three consecutive ignition cycles without a
spring pressure. This blocks the exhaust for the TCC failure reported.
signal fluid and allows solenoid feed drive fluid to feed to D The DTC can be cleared from the PCM history by
TCC signal circuit. The TCC signal fluid pressure acts on using a scan tool.
the TCC regulator valve to regulate line pressure and to D The DTC will be cleared from history when the vehicle
apply fluid pressure to the torque converter clutch shift has achieved 40 warmup cycles without a failure
control valve. When the TCC control valve is in the apply reported.
position, regulated apply fluid pressure is directed D The PCM will cancel the DTC default actions when
through the TCC valve to apply the torque converter the fault no longer exists and the ignition is cycled “off”
clutch. The TCC PWM solenoid is used in conjunction long enough to power down the PCM.
with the TCC reglator valve to regulate fluid to the torque
converter. The TCC PWM solenoid is attached to the Diagnostic Aids
valve body within the transmission.
This DTC detects a continuous open or short to ground or
the PCM and at the transmission connector. Look for
ignition in the TCC circuit or the TCC PWM solenoid. This
possible bent, backed out, deformed or damaged
is a type “B” DTC. terminals. Check for weak terminal tension as well.
Also check for a chafed wire that could short to bare
Conditions For Setting The DTC metal or other wiring. Inspect for a broken wire inside
D Battery voltage is between 10 and 16 volts. the insulation.
D No shift solenoid A DTCs P0751 or P0752 or P0753. D When diagnosing for a possible intermittent short or
D No shift solenoid B DTCs P0756 or P0757 or P0758. open condition, move the wiring harness while
D Ignition is “on”, Engine “run”.
D The PCM commands the solenoid “on” and the Test Description
voltage remains low (zero volts).
D The PCM commands the solenoid “off” and the diagnostic chart:
voltage remains high (B+).
3. This test checks for voltage to the solenoid.
D All conditions met for 0.875 ∼ 1.25 seconds.
4. This test checks the ability of the PCM and wiring to
control the ignition circuit.
9. This test checks the resistance of the TCC solenoid
D Inhibit TCC engagement. and the internal wiring harness.
DTC P1860 TCC PWM Solenoid Electrical

Step Action Yes No
Refer to
Driveability and
Emissions in
when the“Clear Info” function is used.
Is the voltage 0 ? Go to Step 5 Go to Step 6
4 1. Apply brake pedal and select transmission range “D”.
2. Do a test drive, and increase the vehicle speed to TCC “on” at
4th.
Go to Diagnostic
Does the scan tool display DTC P1860 at TCC “ON”? Go to Step 10 Aids
transmission adapter case connector terminal M6–1(A) is shorted
to voltage.
7 Intermittent condition.
Check the wiring harness and terminals between PCM connector
J2 and transmission adapter case connector M–6.
terminal H54–2 and ground.
9 1. Disconnect the transmission adapter case connector M–6.
terminal M6–1(A) and ground.
terminal H54–2 and ground.
DTC P1860 TCC PWM Solenoid Electrical (Cont’d)

Step Action Yes No
12 1. Disconnect the transmission adapter case connector M–6.
terminal M6–1(A) and ground.
transmission 4–way connector terminal H54–2 is shorted to
ground.
14 The wiring harness between transmission 4–way connector H–54
and adapter case connector M–6 is shorted to ground.
15 The TCC solenoid is faulty, or the internal wiring harness from the
TCC solenoid is shorted to ground.
transmission 4–way connector terminal H54–2 is open.
terminal H54–2 and adapter case terminal M6–1(A) is open.
18 The TCC solenoid is faulty, or the internal wiring harness from the
TCC solenoid is open.
19 Check every connection at the PCM.
If OK, replace the PCM. Refer to Powertrain Control Module
(PCM) in Automatic Transmission (4L30–E) section.
20 Check the PCM connector terminal J2–51, transmission 4–way
connector terminal H54–2 and transmission adapter case
connector terminal M6–1(A).
are met:
D The TCC solenoid is commanded “on” and the volts increase
to B+.
D The TCC solenoid is commanded “off” and the volts drop to
zero. Begin diagnosis
DTC P1870 Transmission Component Slipping (TCC Stuck OFF)
D07RY002
Circuit Description D Low (0.8) < TCC Capacity < hi (0.99) for 5 seconds
The PCM monitors the difference in engine speed and
transmission output speed. For example in D3 drive Action Taken When The DTC Sets
range with the ECCC commanded, the engine speed D Only stored in memory.
should closely match transmission output speed. D For lamp illuminate refer to DTC type definition (type
This DTC detects excessive TCC slip when the ECCC is B).
engaged. This is a type “B” DTC.
D The PCM will turn off the MIL and CHECK TRANS
The following conditions are met for three TCC cycles Lamp after three consecutive ignition cycles without a
with reported excessive TCC slip conditions. failure reported.
D No OSS DTCs P0722 or P0723. D The DTC can be cleared from the PCM history by
D No shift solenoid A DTCs P0751 or P0752 or P0753. using a scan tool.
D No shift solenoid B DTCs P0756 or P0757 or P0758. D The DTC will be cleared from history when the vehicle
D No TCC solenoid DTCs P0742 or P1860 or P1870. has achieved 40 warmup cycles without a failure
reported.
D Engine speed is between 1,000 and 3,500 rpm for 0.5
seconds. D The PCM will cancel the DTC default actions when
the fault no longer exist and the ignition is cycled “off”
D Gear range is D4.
D 13% < TPS < 99%
D 50 < Engine Torque < 300 N·m Diagnostic Aids
D TFT is between 20° and 150°C (68° and 302°F). D Range switch malfunction could set a DTC P1870.
D TCC slip speed is between 250 rpm and 800 rpm for 3 D A mechanical failure of the shift solenoids, TCC
times 7 seconds. solenoid, or TCC PWM solenoid could set a DTC
D Vehicle speed is between 25 km/h (15 mph) and 225 P1870.
km/h (158 mph). D Internal transmission failures may set a DTC P1870.
D Speed ratio is between 0.6 and 0.95. D An intermittent or incorrect engine speed signal may
D ECCC is “ON”. set a DTC P1870.
Test Description Range Switch Logic Table

The numbers below refer to the step numbers on the Range Switch Pin
diagnostic chart: Rangeg
Position A B C P(G)
actual selected range. A faulty switch could set a Park ON OFF OFF ON
DTC P1870.
3. This test checks the torque converter for slippage
while in a commanded lockup state. Neutral OFF ON OFF ON
D4 OFF ON ON OFF
D3 ON ON ON ON
2 ON OFF ON OFF
L OFF OFF ON ON
DTC P1870 Transmission Component Slipping (TCC Stuck OFF)

Step Action Yes No
Refer to
Driveability and
Emissions in
4. Apply the brake pedal.
Go to “Range
Does each selected transmission range match the scan tool “TR Switch Logic
Switch” display? Go to Step 3 Table”
3 Drive the vehicle in 4th gear while the TCC is engaged.
At any time is the “TCC Slip Speed” greater than 130 rpm for 8 Go to System Go to Diagnostic
seconds while the TCC is engaged? Diagnosis Charts Aids
Connector List
B-13 H-41
E-53
H-53
(J2)
E-54
H-54
(J1)
H-8 H-55
H-10 H-56
H-11 H-57
H-24 I-9
H-25 M-6
H-32 M-7
M-15 M-25
MANUAL TRANSMISSION 7B–1
TROOPER
TRANSMISSION
MANUAL TRANSMISSION
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 7B–1 Disassembled View . . . . . . . . . . . . . . . . . . . . 7B–13
General Description . . . . . . . . . . . . . . . . . . . . . 7B–2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–16
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–3 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–34
Manual Transmission Assembly . . . . . . . . . . . 7B–4 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–36
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–4 Main Data and Specifications . . . . . . . . . . . . . 7B–62
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–8 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B–64

systems.
7B–2 MANUAL TRANSMISSION
General Description
A07RW023
Diagnosis
Abnormal noise Flywheel pilot bearing worn Replace
Bearings worn or broken (Mainshaft, Replace
counter shaft, and transfer shaft)
Gear tooth contact surfaces worn or Replace
scuffed (Mainshaft, counter shaft,
reverse idler gear and transfer gears)
Splines worn (Mainshaft, Replace
synchronizer clutch hub)
Gear or bearing thrust face seized Replace
Lack of backlash between meshing Replace
gears
Hard Shifting Improper clutch pedal free play Readjust
Change lever sliding portions worn Repair or replace
Regrease
Shift block, shift rod and/or control Replace
box sliding faces worn
Shift arm and synchronizer sleeve Replace worn parts
groove worn
Thrust washer, collar, and/or gear Replace worn parts
thrust faces worn (Mainshaft and
counter shaft thrust play)
Synchronizer parts worn Replace
Walking or Jumping out of gear Detent ball worn Replace
Detent spring weakened or broken Replace
Shift rod and/or control box sliding Replace
faces worn
Shift arm and synchronizer sleeve Replace worn parts
groove worn
Thrust washer, collar, and/or gear Replace worn parts
thrust faces worn (Mainshaft and
counter shaft thrust play)
Bearings worn or broken Replace
Splines worn (Mainshaft, Replace
synchronizer hub)
Synchronizer spring weakened or Replace
broken
Oil leakage Loose drain plug(s) and/or filler Tighten
plug(s) Replenish oil
Defective or improperly installed Replace
gasket(s)
Oil seal worn or scratched Replace
Manual Transmission Assembly

Removal 9. Remove the front propeller shaft.
NOTE: Apply alignment marks on the flange at both the
NOTE: Before remove the transmission and transfer
front and rear sides.
assembly from the vehicle, change the transfer mode to
2WD using push button on dash panel.
3. Remove the gear control lever knob.
4. Remove the front console assembly.
5. Remove the grommet assembly.
6. Remove the transmission control lever and transfer
control lever.
401RS003
10. Disconnect the reverse lamp switch, 4WD indicator

switch, and 1-2 indicator switch harness connectors.
235RX001
7. Remove transfer protector.

8. Remove the rear propeller shaft.
NOTE: Apply alignment marks on the flange at the both
front and rear side.
230RW005
401RS002
11. Disconnect the speed sensor and 2WD-4WD 13. Remove two transmission harness clamps from the
actuator harness connectors. transmission case and bracket .
225RW007 220RS028
12. Disconnect the 4WD indicator harness connector. 14. Remove four fuel pipe bracket.
220RW006
141RW024
15. Remove the heat protector. 16. Remove the slave cylinder.
225RW006 206RW002
D Remove the dust cover from the clutch housing. 27. Use the clutch release bearing remover J–39207 to
17. Support the transfer case with a jack. disconnect the clutch release bearing from the clutch
pressure plate.
18. Remove two engine rear mount nuts.
220RS002
022RT002
19. Remove third crossmember. Release bearing disconnection

20. Disconnect four oxygen sensor connectors from the 1. Pull the shift fork toward the transmission to press
transmission harness. the clutch release bearing against the clutch.
21. Remove the right front exhaust pipe and catalytic 2. Insert the clutch release bearing remover
converter assembly. between the wedge collar and the release
22. Remove the harness heat protector. bearing.
23. Remove two engine rear mount bolts. 3. Turn the remover to separate the release bearing.
24. Remove the rear mount from the transmission.
25. Remove three flywheel under cover.
26. Support the transmission with a transmission jack
and then remove jack from the transfer case side.
220RS001
NOTE: Be sure not to insert the remover between the
wedge collar and the clutch.
220RS004
28. Remove the transmission retaining nuts and bolts.

29. Remove the transmission assembly with transfer
case from the vehicle.
NOTE: Remove the transfer case from the transmission
assembly if the transmission disassembly required.
Refer to Transfer Case in Drive Line/Axle section.
Installation
1. Apply a thin coat of molybdenum disulfide grease to
the top gear shaft spline.
220RW063 2. Slowly operate the transmission jack until the front of
transmission is aligned with the rear of the engine.
The slope of the engine and the transmission must be
the same.
3. Align the top gear shaft spline with the clutch driven
plate spline.
220RW064
220RS005
4. Install the transmission to the engine.

Tighten the transmission retaining nuts and bolts.
225RX001
5. Apply a force of about 113 N (26 lb) to the tip of the

shift fork in the direction of the transmission to engage
the clutch pressure plate and release bearing.
NOTE: A clicking sound is heard when the release
bearing and the tip of the diaphragm spring engage each
other.
Check to see if they are securely engaged by pushing the
tip of the shift fork toward the engine while applying a
force of about 25 N (5.5 lb). If the shift fork will not move,
then they are securely engaged.
220RS006
6. Install three flywheel under cover.

7. Install the engine rear mount to the transmission case 16. Install the slave cylinder heat protector to the slave
and tighten the fixing bolts specified torque. cylinder.
Torque: 41 N·m (30 lb ft) 17. Install harness heat protector.
8. Install the harness heat protector.
9. Install the right front exhaust pipes and catalytic
converter assembly.
Torque
Exh. pipe to exh. manifold: 67 N·m (49 lb ft)
Exh. pipe flange bolt: 43 N·m (32 lb ft)
10. Connect four oxygen sensor connectors to the
transmission harness.
11. Install the third crossmember to the frame and tighten
the fixing bolts specified torque.
12. Tighten the engine rear mount nuts specified torque.
13. Remove the transmission jack.
14. Apply the grease to top hole portion of the shift fork.
15. Install the slave cylinder and tighten the fixing bolts
specified torque. 225RW006
18. Install four fuel pipe bracket.

Install the clutch dust cover to the clutch housing and
tighten the fixing bolts specified torque.
220RS007
141RW024
19. Install bracket and two transmission harness clamps 20. Connect the speedometer sensor and 2WD–4WD
to the transmission case. actuator harness connector.
220RS028 225RW007
21. Connect the backup lamp switch, 4WD indicator 24. Install transfer protector and tighten the fixing bolts
switch, and 1-2 indicator switch harness connectors. specified torque.
25. Install the transmission control lever and transfer
control lever.
26. Install the grommet assembly.
27. Install the front console assembly.
28. Install the gear control lever knob.
230RW005
22. Install the front propeller shaft and tighten the fixing
bolts and nuts specified torque.
23. Install the rear propeller shaft and tighten the fixing
bolts and nuts specified torque.
Torque: 63 N·m (46 lb ft) 235RX001

30. Install engine hood.
Disassembled View
226RW182
Legend (19) 1st Gear

(1) Snap Ring (20) 1st Gear Bearing Spacer
(2) Bearing (21) 1st Gear Needle Roller Bearing
(3) Top Gear Shaft (22) 1st Gear Thrust Washer
(4) Block Ring (23) Mainshaft Bearing
(5) Roller Bearing (24) Snap Ring
(6) Snap Ring (25) 5th Gear
(7) Clutch Hub No.2 Assembly (26) Snap Ring
(8) 3rd Block Ring (27) Intermediate Plate
(9) 3rd Gear (28) Bearing Retainer
(10) 3rd Gear Needle Roller Bearing (29) Snap Ring
(11) Mainshaft (30) Front Bearing Assembly
(12) Thrust Washer Pin (31) Counter Gear Shaft
(13) 2nd Gear Needle Roller Bearing (32) Thrust Washer Pin
(14) 2nd Gear (33) Reverse Idle Gear
(15) Synchronizer Assembly (34) Reverse Idle Gear Shaft
(16) Clutch Hub No.1 Assembly (35) Counter Gear Shaft Center Bearing
(18) Synchronizer Assembly (37) Thrust Washer
(38) Roller Bearing (42) Hub Sleeve No.3
(39) Counter 5th Gear (43) 5th Gear Spline Piece
(40) Reverse Block Ring (44) Snap Ring
(41) Synchronizer Assembly
226RW181
Legend (9) Reverse Shift Arm Bracket

(1) 3rd-4th Shift Arm (10) E–Ring
(2) 1st-2nd Shift Arm (11) Reverse Shift Arm No.2
(3) 3rd-4th Shift Rod (12) Reverse Shift Arm No.1
(4) Ball (13) 5th Reverse Shift Rod
(5) Spring (14) Spring Pin
(6) 1st-2nd Shift Rod (15) 5th Shift Arm
(7) Snap Ring (16) Reverse Shift Rod
(8) Interlock Pin
220RY002
Legend (11) Filler Plug

(1) Release Bearing and Shift Fork (12) Oil Receiver Pipe
(2) Clutch Housing (13) Reverse Restrict Pin
(3) Front Cover (14) Gear Control Rod
(4) Snap Ring (15) Transfer Adapter
(5) Snap Ring (16) Plug
(6) 1st and 2nd Switch (17) Gear Control Box
(7) Drain Plug (18) Shift Lever Housing
(8) Backup Light Switch (19) Oil Seal
(9) Plug (20) Plug
(10) Transmission Case
Disassembly 3. Remove the switch.

1. Remove backup light switch (6) and gasket.
1. Remove the drain plag and filler plug.
2. Remove 1st and 2nd switch (8) and gasket.
1. Remove the drain plug (1) and gasket.
2. Remove the filler plug (2) and gasket.
220RY001
4. Remove the clutch housing.

220RW007 1. Remove the 9 bolts.
2. Remove the clutch release bearing and shift fork.
1. Remove the clutch release bearing (3) from the
front cover.
2. Remove the split pin (4). Remove the shaft from
the under. Remove the shift fork (5).
241RW001
220RW086
2. Using a plastic hammer, carefully tap the clutch 6. Remove transfer adapter.
housing. 1. Using a hexagon wrench, remove the plug (1).
220RW008 220RW010
5. Remove gear control box and gasket. 2. Using a pin punch and hammer, drive out the
1. Remove the 6 bolts, gear control box and gasket. slotted spring pin (2).
230RW001 230RW002
3. Using the M8 × 1.25 bolt, remove the gear control 5. Using a plastic hammer, tap the transfer adapter.
rod and the shift lever housing.
NOTE:
NOTE: Turn the M8 bolt a few times, before remove the D Be careful not to lose the pin.
gear control rod.
D Cover the mainshaft splines with adhesive tape.
This will prevent damage to the oil seal lip.
220RW098
4. Remove the 10 bolts and clamp.

220RW015
7. Disassemble the transfer adapter assembly.

1. Using a torx socket wrench(T40), remove the
plug.
220RW016
220RW013
2. Using a pin punch and hammer, drive out the 4. Remove the oil seal.
slotted spring pin. Remove the reverse restrict
5. Using socket hexagon wrench, remove the plug.
pin.
220RW014
220RW012
8. Remove the front cover.
3. Remove the oil receiver pipe.
1. Remove the 8 bolts.
220RW011
220RW018
2. Using a plastic hammer, carefully tap the front 10. Remove the transmission case.
cover. 1. Using a snap ring expander, remove the 2 snap
rings (1)(2).
220RW017
9. Remove the front cover oil seal. 226RW004
1. Mount the front cover through the aluminum plate 2. Using a plastic hammer, carefully tap the
in a vise. transmission case.
2. Using screwdriver, remove oil seal (1).
220RW020
220RW019
11. Mount the intermediate plate. 13. Remove the shift arm set bolt.
1. Mount the intermediate plate through the 1. Remove the 2 bolts from the shift arm.
aluminum plate in a vise.
226RW023
226RW005 14. Remove the counter 5th gear.

12. Remove the slotted spring pin. 1. Using 2 screwdrivers and hammer, tap out the
1. Using a pin punch and hammer, drive out the pin snap ring.
from the arm.
226RW024
226RW025
2. Using remover J–42794 and attachment 4. Remove the synchronizer pull ring, synchronizer
J–42988, remove the 5th gear spline piece. cone ring, and synchronizer outer ring from hub
sleeve No.3.
226RW021
3. Remove the hub sleeve No.3, block ring set, 226RW066
counter 5th gear, bearing and 5th shift arm. 5. Remove the reverse block ring from the hub
sleeve No.3. Remove the 3 inserts and 3
compression springs.
220RW101
226RW067
15. Remove the thrust washer. 17. Remove the reverse idle gear.
1. Remove the thrust washer from counter gear 1. Pull out the shaft foward the rear and remove the
shaft. reverse idle gear.
2. Remove the thrust washer pin from counter gear
shaft.
226RW020
18. Remove the counter gear shaft.

226RW018
1. Using snap ring plier, remove counter gear shaft
16. Remove the bearing plate. center bearing snap ring.
1. Remove the 4 bolts and bearing retainer.
226RW015
226RW016
2. Using remover J–42795 and attachment 19. Disassemble the counter gear shaft assembly.
J–42988, remove counter gear shaft center 1. Using snap ring pliers, remove the counter gear
bearing. shaft front bearing snap ring.
NOTE: Be careful not to drop the counter gear, when
removing the bearing.
226RW065
2. Using bearing separator J–22912–01 and a

226RW036
press, remove the bearing.
3. Remove the counter gear from intermediate
plate.
226RW068
226RW030
20. Remove the top gear shaft. 21. Disassemble the top gear shaft assembly.
1. Remove the top gear shaft from mainshaft. 1. Check for wear or damage.
NOTE: Don’t fall needle roller bearing.
226RW033
2. Remove the front bearing shaft snap ring.

226RW029
2. Remove the 4th block ring and roller bearing.
226RW062
226RW031
3. Using bearing separator J–22912–01 and a 2. Using a plastic hammer, tap the 5th-reverse shift
press, remove the bearing. rod at the reverse shift side.
226RW069 226RW034
22. Remove the mainshaft. 3. Remove the intermediate plate from a vise.
1. Remove mainshaft bearing snap ring. 4. Remove the mainshaft, 1st-2nd shift arm and
3rd-4th shift arm.
226RW035
226RW014
23. Disassemble the main shaft assembly. 2. Inspect each gear radial clearance.
1. Inspect each gear thrust clearance. 1. Using a dial indicator, measure the radial
1. Using thickness gauge, inspect thrust clearance of each gear.
clearance (1st gear, 3rd gear).
Gear Standard Clearanse
1st 0.020 – 0.074 mm (0.00078 – 0.00291 in)
2nd 0.015 – 0.068 mm (0.00059 – 0.00268 in)
3rd 0.015 – 0.068 mm (0.00059 – 0.00268 in)
226RW077
2. Mount the mainshaft through the aluminum

plate in a vise.
3. Using a dial indicator, measure each gear
thrust clearance.
Gear Standard Clearanse 226RW071
1st 0.15 – 0.45 mm (0.0059 – 0.0177 in) 3. Using 2 screwdrivers and hammer, tap out the
snap ring.
2nd 0.10 – 0.25 mm (0.0039 – 0.0098 in)
3rd 0.10 – 0.25 mm (0.0039 – 0.0098 in)
226RW053
226RW070
4. Using bearing separator J–22912–01 and a 6. Using 2 screwdrivers and hammer, tap out snap
press, remove the following parts. ring.
1. 5th gear (1).
2. Mainshaft bearing (2).
3. 1st gear thrust washer (3).
4. 1st gear (4).
226RW073
7. Using bearing separator J–22912–01 and a

press, remove the following parts.
1. Clutch hub No.1 assembly (1).
2. Synchronizer assembly (2).
226RW072
3. 2nd gear (3).
5. Remove following parts from mainshaft.
1. Synchronizer assembly (1). 4. 2nd gear needle roller bearing (4).
2. 1st gear thrust washer pin (3).
3. 1st gear needle roller bearing (4).
4. 1st gear bearing spacer (2).
226RW074
226RW146
8. Remove the reverse gear from clutch hub No.1. 11. Using a press, remove following parts.
9. Remove the 3 inserts and 3 compression springs. 1. Clutch hub No.2 assembly (1).
D When removing the inserts, push the insert 2. 3rd block ring (2).
spring with a screwdriver. 3. 3rd gear (3).
4. 3rd gear needle roller bearing (4).
226RW075

226RW091
NOTE: Don’t damage the bearing surface. 12. Using screwdriver, remove the 2 insert springs,
hub sleeve No.2, clutch hub No.2 and 3 inserts.
226RW076
226RW090
24. Remove the shift parts and interlock parts. 4. Using a magnetic finger, remove 3 springs and
1. Mount the intermediate plate through the balls.
aluminum plate in a vise.
2. Using a plastic hammer, tap the 5th shift rod on
the neutral.
226RW049
5. Using 2 screwdrivers and a hammer, remove 2

snap rings from each shift fork rod.
226RW052
3. Using a torx socket wrench(T40), remove the 4

plugs.
226RW048
226RW050
6. Pull out the 3rd–4th shift rod at the rear. 8. Pull out the 1st–2nd shift rod at the rear.
226RW047 226RW045
7. Using a magnetic finger, remove the interlock pin 9. Using a magnetic finger, remove the interlock pin.
and straight pin.
226RW042
226RW043
10. Using 2 screwdrivers and a hammer, remove 2 12. Using a magnetic finger, remove the interlock pin
snap rings. from the intermediate plate. Remove the ball
from the reverse shift arm No.1.
226RW041
11. Pull out the 5th-reverse shift rod at the front. 226RW039
13. Pull out at the rear reverse shift rod, reverse shift
arm No.1 and reverse shift arm No.2 at the same
time.
226RW040
226RW038
14. Pull out reverse shift rod from reverse shift arm 16. Remove the reverse shift arm No.2 E–ring.
No.1. Remove the reverse shift arm No.2 from reverse
shift arm No.1.
NOTE: Be sure remove at the rear.
226RW089
226RW055
17. Remove the 2 bolts and reverse shift arm bracket.
15. Using a magnetic finger, remove the ball and
spring from reverse shift arm No.1.
226RW054
226RW056
Inspection 4. Using a inside dial indicator, measure the gear

inside diameter.
1. Counter 5th gear radial clearance.
Standard: 38.015 – 38.040 mm
1. Install the following parts to the counter gear (1.49665 – 1.49763 in)
shaft.
1. Counter 5th gear thrust washer pin (1).
2. Counter 5th gear thrust washer (2).
3. Counter 5th gear needle bearing( 3).
4. Counter 5th gear (4).
226RW085
2. 5th-reverse shift arm and hub sleeve No.3 clearance.

1. Using a vernier caliper, measure the 5th-reverse
shift arm thickness.
Reference: 10.2 mm (0.402 in)
226RW088
2. Using a vernier caliper, measure the center
2. Mount the counter gear shaft through the
groove of hub sleeve No.3. Calculate the
aluminum plate in vise.
clearance between the hub sleeve No.3 and shift
3. Using a dial indicator, measure the counter 5th arm.
gear radial clearance.
Standard: 0.26 – 0.84 mm (0.0102 – 0.0331 in)
Standard: 0.015 – 0.068 mm
Reference: Center groove dimension 10.5mm
(0.00059 – 0.00268 in)
(0.413 in)
226RW183
226RW086
3. Reverse block ring set. 3. If the clearance exceeds the maximum, measure
1. Using a thickness gauge, measure the clearance the gear inside diameter and shaft diameter.
between the counter 5th gear spline piece and Standard
reverse block ring.
Shaft Diameter: 23.979 – 24.000 mm
Standard: 0.7 – 1.7 mm (0.028 – 0.067 in) (0.94405 – 0.94488 in)
Gear Diameter: 24.040 – 24.061 mm
(0.94645 – 0.94728 in)
226RW084
4. Reverse idle gear and reverse idle gear shaft.

1. Mount the reverse idle gear and reverse idle gear 226RW082
shaft in a vise. 5. Reverse shift arm No.2 thrust clearance.

2. Using a dial indicator, measure the reverse idle 1. Using a thickness gauge, measure the clearance
gear radial clearance. between the reverse idle gear and shift arm No.2.
Standard: 0.040 – 0.082 mm (0.0016 – 0.0032 in) Standard: 0.05 – 0.35 mm (0.002 – 0.014 in)
226RW081
226RW083
Reassembly 3. Using a snap ring expander, install the new snap

ring.
1. Install the top gear shaft assembly.
1. Using installer J–42904 and a press, install a new
bearing.
NOTE: Outer race snap ring groove (1) toward front.
226RW062
4. Install the 4th block ring.
226RW092
2. Select a snap ring that will allow minimum axial

play.
Mark Thickness
A 2.10 – 2.15 mm (0.083 – 0.085 in)
B 2.15 – 2.20 mm (0.085 – 0.087 in)
C 2.20 – 2.25 mm (0.087 – 0.089 in)
D 2.25 – 2.30 mm (0.089 – 0.091 in)
E 2.30 – 2.35 mm (0.091 – 0.093 in)
F 2.35 – 2.40 mm (0.093 – 0.095 in)
G 2.40 – 2.45 mm (0.095 – 0.097 in)
226RW063
226RW061
5. Using a thickness gauge, measure the clearance 3. Inspect block ring.
between the 4th block ring back and gear spline 1. Using a thickness gauge, measure the clearance
end. between the synchronizer ring back and gear
Standard: 0.75 – 1.65 mm (0.030 – 0.065 in) spline end.
1st 0.80 – 1.60 mm (0.032 – 0.063 in)
2nd 0.65 – 1.75 mm (0.026 – 0.069 in)
3rd 0.75 – 1.65 mm (0.030 – 0.065 in)
226RW064
6. Check the braking effect of the block ring. Turn

the block ring in one direction while pushing it to
the gear cone. Check that the ring locks. If it does
not lock, replace the block ring.
226RW105
2. Turn the synchronizer ring in one direction while

pushing it to the gear cone. Check that the ring
locks.
226RW060
7. Install the needle roller bearing.

2. Reassemble the mainshaft assembly.
NOTE: Apply all parts with gear oil before installing them.
226RW106
4. Inspect hub sleeve and shift arm.
1st–2nd shift arm
1. Using a vernier caliper, measure center groove of
the 1st–2nd shift arm.
Reference: 5.28 mm (0.208 in)
2. Using a vernier caliper, measure flange of the
reverse gear. Calculate the clearance between
the reverse gear and shift arm.
Reference: Reverse gear flange thickness 5.0
mm (0.197 in)
Standard: 0.15 – 0.41 mm (0.006 – 0.016 in)
226RW095
5. Inspect clutch hub and hub sleeve.

1. Check for wear or damage.
2. Install the hub sleeve to the clutch hub, and check
sliding smoothly.
226RW093
3rd–4th shift arm

1. Using a vernier caliper, measure tip of the shift
arm thickness.
Reference: 10.0mm (0.39 in)
2. Using a vernier caliper, measure center groove of
the hub sleeve No.2. Calculate the clearance
between the hub sleeve No.2 and shift arm.
Reference: Center groove dimension 10.2 mm
(0.402 in)
226RW094
Standard: 0.15 – 0.35 mm (0.006 – 0.014 in) 6. Inspect gear inside diameter.
1. Using a inside dial indicator, measure the gear
inside diameter.
Gear Standard Diameter
1st 46.015 – 46.040 mm (1.8116 – 1.8126 in)
2nd 53.015 – 53.040 mm (2.0872 – 2.0882 in)
3rd 44.015 – 44.040 mm (1.7329 – 1.7339 in)
2. Using a micrometer, measure the mainshaft
flange thickness.
226RW096
7. Inspect mainshaft.
1. Using a micrometer, measure the outer diameter
of the mainshaft journal.
226RW079
Mea- 3. Install the mainshaft to V-blocks.

sure
Standard 4. Use a dial indicator to measure the mainshaft
Positio
n central portion run-out.
A 37.984 – 38.000 mm (1.4954 – 1.4961 in) Standard: less than 0.015 mm (0.0006 in)
B 46.984 – 47.000 mm (1.8498 – 1.8504 in)
C 38.979 – 38.995 mm (1.5346 – 1.5352 in)
226RW097
226RW078
8. Install 3rd gear. NOTE:
1. Install the 3rd gear needle bearing, 3rd gear and D Align the block ring slots with the inserts.
3rd block ring to the mainshaft. D Check that the gear rotates smoothly.
226RW098
226RW100
9. Install the clutch hub No.2.
1. Install the clutch hub No.2 and hub sleeve No.2. play.
NOTE: Be careful the direction of the clutch hub No.2, as
shown. Mark Thickness
2. Using a screwdriver, install 3 inserts and 2 A 1.80 – 1.85 mm (0.071 – 0.073 in)
springs. B 1.85 – 1.90 mm (0.073 – 0.075 in)
NOTE: Position the insert springs so that their end gaps C 1.90 – 1.95 mm (0.075 – 0.077 in)
are not in line.
D 1.95 – 2.00 mm (0.077 – 0.079 in)
E 2.00 – 2.05 mm (0.079 – 0.081 in)
F 2.05 – 2.10 mm (0.081 – 0.083 in)
G 2.10 – 2.15 mm (0.083 – 0.085 in)
226RW099
3. Using installer J–42797 and a press, install the

clutch hub No.2 and hub sleeve No.2 to the
mainshaft.
226RW102
5. Using a snap ring expander, install the new snap 10. Install the 2nd gear.
ring. 1. Install the synchronizer ring set NO.1 to the 2nd
NOTE: Be careful not to damage the bearing surface. gear.
NOTE: Align the nail of middle ring with gear spline slots.
226RW101
6. Using a thickness gauge, inspect the 3rd gear 226RW104
thrust clearance. 2. Install the needle roller bearing, 2nd gear and 2nd
Standard: 0.10 – 0.25mm (0.004 – 0.010 in) gear block ring set to the mainshaft.
226RW107
226RW103
11. Install the clutch hub No.1.
1. Install the 3 inserts and 3 insert springs to the
clutch hub No.1.
Reference: While pushing the insert spring
with a screwdriver, install the inserts.
226RW110

play.
Mark Thickness
226RW108 A 2.30 – 2.35 mm (0.091 – 0.093 in)
2. Install the clutch hub No.1 to the reverse gear. B 2.35 – 2.40 mm (0.093 – 0.095 in)
NOTE: Check the clutch hub No.1 installing direction, as C 2.40 – 2.45 mm (0.095 – 0.097 in)
shown.
D 2.45 – 2.50 mm (0.097 – 0.098 in)
E 2.50 – 2.55 mm (0.098 – 0.100 in)
F 2.55 – 2.60 mm (0.100 – 0.102 in)
G 2.60 – 2.65 mm (0.102 – 0.104 in)
226RW109

hub No.1 by retaining the reverse gear.
NOTE:
D Align the projection of inner ring with hub No.1 slots.
D Check that the gear rotates smoothly. 226RW111
5. Using a screwdriver and hammer, install the snap 1. Install the following parts:
ring. 1. 1st gear bearing spacer (4).
NOTE: Be careful not to damage the bearing surface. 2. 1st gear needle roller bearing (3).
6. Check that the gear rotates smoothly. 3. Synchronizer assembly (2).
4. 1st gear (1).
NOTE:
D Align the projection of inner ring with hub No.1 slots.
D Check that the gear rotates smoothly.
226RW112
7. Using a dial indicator, measure the 2nd gear

thrust clearance.
Standard: 0.10 – 0.25mm (0.004 – 0.010 in)
226RW114
2. Install the 1st gear thrust washer pin and 1st gear
thrust washer to the mainshaft.
NOTE: Align the straight pin with the thrust washer slot.
226RW113
12. Install the 1st gear.
226RW115
13. Install the mainshaft center bearing. Mark Thickness
C 2.75 – 2.80 mm (0.108 – 0.110 in)
mainshaft center bearing.
D 2.80 – 2.85 mm (0.110 – 0.112 in)
NOTE: Center bearing snap ring groove toward rear.
E 2.85 – 2.90 mm (0.112 – 0.114 in)
F 2.90 – 2.95 mm (0.114 – 0.116 in)
G 2.95 – 3.00 mm (0.116 – 0.118 in)
H 3.00 – 3.05 mm (0.118 – 0.120 in)
J 3.05 – 3.10 mm (0.120 – 0.122 in)
K 3.10 – 3.15 mm (0.122 – 0.124 in)
L 3.15 – 3.20 mm (0.124 – 0.126 in)
M 3.20 – 3.25 mm (0.126 – 0.128 in)
N 3.25 – 3.30 mm (0.128 – 0.130 in)
P 3.30 – 3.35 mm (0.130 – 0.132 in)
226RW117
2. Using a thickness gauge, measure 1st gear thrust

clearance.
Standard: 0.10 – 0.45mm (0.004 – 0.018 in)
226RW116
3. Using a screwdriver and hammer, install the new

snap ring.
226RW118
14. Install the 5th gear.

5th gear.
play.
226RW127
15. Inspect each gear radial clearance. 3. Select a snap ring that will allow minimum axial
1. Mount the mainshaft through the aluminum plate play.
in a vise.
Mark Thickness
2. Using a dial indicator, measure the radial
clearance of each gear. A 2.00 – 2.05 mm (0.079 – 0.081 in)
B 2.05 – 2.10 mm (0.081 – 0.083 in)
C 2.10 – 2.15 mm (0.083 – 0.085 in)
1st 0.020 – 0.073 mm (0.0008 – 0.0029 in)
D 2.15 – 2.20 mm (0.085 – 0.087 in)
2nd 0.015 – 0.068 mm (0.0006 – 0.0027 in)
E 2.20 – 2.25 mm (0.087 – 0.089 in)
3rd 0.015 – 0.068 mm (0.0006 – 0.0027 in)
F 2.25 – 2.30 mm (0.089 – 0.091 in)
226RW071
16. Install the counter gear shaft. 226RW128
1. Check the new counter front bearing inner race 4. Using a snap ring expander, install the new snap
and the side race, as shown. ring.
counter gear shaft front bearing.
226RW129
226RW119
17. Install the front cover. 3. Install the oil receiver pipe.
1. Using installer J–42801, grip J–8092 and a
hammer, drive in a new oil seal.
Drive in depth (from cover end): 11.7 ± 0.5 mm
(0.46 ± 0.02 in)
2. Apply grease to the seal lip.
220RW011
4. Install the reverse restrict to the transfer adapter.
220RW023
18. Install the transfer adapter.

1. Using installer J –42802, and a hammer drive in a
new oil seal.
Drive in depth (from transfer adapter):
10.95 ± 0.5 mm (0.431 ± 0.02 in)
2. Apply grease to the oil seal lip.
226RW059
220RW073
5. Using a pin punch and hammer, drive in the 9. Using hexagon wrench, install and torque the
slotted spring pin. plug.
226RW058
6. Clean up the plug and plug hole. 220RW014
7. Apply sealant to the plug threads. (THREE BOND 19. Install the reverse shift arm No.1 and reverse shift
1344 or equivalent) arm No.2.
8. Using a torx socket wrench(T40), install and 1. Mount the intermediate plate through the
torque the plug. aluminum plate in a vise.
226RW057
220RW013
2. Using 2 bolts, install reverse shift arm bracket. 4. Install reverse shift arm No.2 to the reverse shift
arm bracket.
226RW012
226RW054
20. Install the reverse shift rod.
3. Install reverse shift arm No.2 to the reverse shift
arm No.1. Using screwdriver and a hammer, 1. Install the reverse shift arm No.1 compression
install the new E-ring. spring and ball to the reverse shift arm No.1.
226RW125
226RW138
2. Install the reverse shift rod from the rear side by 3. Put in the reverse-5th shift rod from the front.
pushing the ball on using a screwdriver.
226RW011
226RW126 4. Using a screwdriver and a hammer, install the 2

21. Install the reverse-5th shift rod. new shift rod snap rings to the 5th-reverse shift
1. Install the reverse shift arm No.1 lock ball to the rod and reverse shift rod.
reverse shift arm No.1.
2. Install the interlock pin to the intermediate plate.
226RW037
226RW039
22. Install 1st–2nd shift rod. 23. Install 3rd–4th shift rod.
1. Install the interlock pin to the intermediate plate. 1. Install the straight pin and interlock pin to the
intermediate plate.
226RW042
2. Put in the 1st–2nd shift rod from the rear. 226RW043
2. Put in the 3rd–4th shift rod from the rear.
226RW044
226RW046
24. Install the interlock parts. 5. Using a torx socket wrench(T40) install and
1. Using a screwdriver and hammer, 2 new shift rod torque the 4 plugs.
snap rings to the 1st–2nd and 3rd–4th shift rod. Torque: 18.5 N·m (13.5 lb ft)
226RW051
226RW050
2. Install the 3 shift detent ball and springs to the 25. Install mainshaft assembly.
intermediate plate.
NOTE: Coat all parts with gear oil before installing them.
1. Using a plastic hammer, tap the 5th-reverse shift
rod at the reverse shift.
226RW049
3. Clean up the plug hole.

4. Apply sealant to the plug threads. 226RW180
sealant: three bond 1344 or equivalent

2. Install the shift arm No.1 and No.2 to the 4. Using a snap ring expander, install the snap ring.
mainshaft.
226RW035
226RW010 5. Using a plastic hammer, tap the 5th-reverse shift

3. Using a plastic hammer, tap the intermediate rod at the neutral shift.
plate and install the mainshaft. Through the shift
arm No.1 and No.2 to the shift rod.
226RW008
226RW009
26. Install the top gear shaft. 2. Using installer J–42796 and a hammer, drive in
1. Align the projection of the hub No.2 with the the center bearing as shown.
synchronizer ring slots, and install the top gear NOTE: Outer race snap ring groove toward rear.
shaft assembly to the mainshaft.
2. Check that the gear rotates smoothly.
226RW007
Reference: Drive in the counter rear bearing

226RW006 by tapping on the front end of the counter
27. Install the counter gear shaft. shaft.
1. Temporarily install the counter gear shaft to the
intermediate plate.
226RW022
226RW028
28. Install the reverse idle gear. 30. Install the 5th gear thrust washer.
1. Install the reverse idle gear and reverse idle gear 1. Install the 5th gear thrust washer pin to the
shaft. counter gear shaft.
NOTE: 2. Install the 5th gear thrust washer to the counter
gear shaft.
D Insert the reverse idle gear shaft with the slot toward
rear. NOTE: Thrust washer must be assembled with the
D Install the reverse idle gear with the reverse shift arm chamfered face of the washer toward the front.
No.2.
226RW185
226RW019 31. Install the counter 5th gear.

29. Install the bearing plate. 1. Install the 3 inserts and 3 compression springs to
1. Align the bearing plate to groove of the reverse the reverse block ring.
idle gear shaft. Reference: Push the 3 inserts with the 3 com-
Torque: 12.5 N·m (109 lb in) pression springs to the reverse synchronizer
ring.
226RW016
226RW120
2. Install the synchronizer outer ring, synchronizer 4. Install the hub sleeve No.3 and reverse block ring
cone ring, and synchronizer pull ring to the set to the counter 5th gear.
reverse block ring.
NOTE: Check the hub sleeve No.3 direction, as shown.
Reference: While pushing the 3 inserts,
install the synchronizer ring assembly to the
hub sleeve No.3.
226RW121
3. Turn to 30 degree the reverse synchronizer pull

ring.
226RW184
5. Slide the hub sleeve No.3.
226RW080
226RW123
6. Install the counter 5th gear bearing, counter 5th 8. Using thickness gauge, measure the counter 5th
gear and reverse block ring set to the counter gear thrust clearance.
gear shaft, through the 5th reverse shift arm to the
Standard: 0.10 – 0.35mm (0.004 – 0.014 in)
5th reverse shift rod.
220RW100
220RW101
7. Using installer J–42796 and a press, install
play.
counter 5th gear spline piece.
NOTE: Mark Thickness
D Align the projection of the cone ring to the holes of the A 2.80 – 2.85 (0.110 – 0.112 in)
5th gear spline piece. B 2.85 – 2.90 (0.112 – 0.114 in)
D Check that the gear rotates smoothly.
C 2.90 – 2.95 (0.114 – 0.116 in)
D 2.95 – 3.00 (0.116 – 0.118 in)
E 3.00 – 3.05 (0.118 – 0.120 in)
F 3.05 – 3.10 (0.120 – 0.122 in)
G 3.10 – 3.15 (0.122 – 0.124 in)
226RW013
226RW027
10. Install the new snap ring. 33. Install the shift arm slotted pin.
1. Using a pin punch and a hammer, drive in the
slotted pin to the shift arm.
226RW026
32. Install the shift arm bolts.

1. Install and torque the 2 shift arm bolts. 226RW025
34. Install the transmission case.

Torque: 19.5 N·m (14 lb ft)
1. Clean up the fitting surface.
2. Apply recommended liquid gasket (THREE
BOND 1281 or equivalent), as shown.
NOTE:
D Don’t dry the liquid gasket.
226RW023
220RW024
3. Stand the transmission by the wood blocks. NOTE:
4. Using a plastic hammer, tap the transmission D Don’t dry the liquid gasket.
case and attach it to the intermediate plate.
NOTE: Be careful not to add over force to bearing.
220RW025
3. Clean up and dry the bolts.

220RW022
4. Apply thread sealant (THREE BOND 1344 or
5. Using a snap ring expander, install the front equivalent) to the 8 bolts.
bearing shaft snap ring (1) and counter gear shaft 5. Using 8 bolts, install the front cover to the
bearing snap ring (2). transmission case.
Torque: 16.5 N·m (12 lb ft)
NOTE:
D Tighten the all bolts evenly.
D Be careful not to damage the oil seal.
226RW004
6. Turn over the transmission.

35. Install the front cover.
BOND 1281 or equivalent), as shown. 220RW018
6. Check that the top gear shaft and mainshaft 4. Using 10 bolts, install the transfer adapter.
rotate.
36. Install the transfer adapter.
NOTE:
D Tighten the all bolts evenly.
BOND 1281 or equivalent), as shown. D Don’t damage the lip of the oil seal.
D Install the wire clamp (9) to the transfer adapter.
NOTE:
D Don’t dry the liquid gasket.
220RW083
37. Install the gear control box.

220RW026
1. Align the projection of the shift lever housing to
3. Using a plastic hammer, tap the transfer adapter the shift rod groove, and install the gear control
and attach it to the intermediate plate. rod.
220RW034 230RW003
2. Using a pin punch and hammer, drive in the 6. Using 6 bolts, install the gear control box through
slotted spring pin (2) to the shift lever housing. the gasket.
NOTE: Be carefull not to drop the slotted spring pin. Torque 18 N·m (13 lb ft)
230RW002 230RW001
3. Apply sealant (THREE BOND 1344 or 38. Install clutch housing.

equivalent) to the plug (1) thread. 1. Install the clutch housing to the transmission
case.
4. Using hexagon wrench, install and torque the
plug (1). Torque: 36 N·m (27 lb ft)
Torque: 18 N·m (13 lb ft) NOTE: Tighten the all bolts evenly.
220RW010 241RW001
5. Clean up the bolts and bolt hole.

39. Install the switches.
1. Install the new gasket to the 1st and 2nd switch.
2. Install the 1st and 2nd switch assembly (8).
3. Install the new gasket to the backup light switch.
4. Install the backup light switch assembly (6).
220RW086
41. Install the drain plug and filler plug.

1. Install the drain plug (1) through the new gasket.
2. Install the filler plug (2) through the new gasket.
Reference: Plug after the gear oil fill in.
220RY001
40. Install the clutch release bearing (3) and clutch shift
fork (5).
1. Apply the clutch release grease.
1. Fitting surface of the cylinder push rod.
2. Fitting surface of the release bearing hub.
3. The hole of the fork split pin (4).
2. Apply the clutch release grease.
1. The spline surface of the top gear shaft.
3. Install the clutch shift fork (5).
4. Install the snap pin.
5. Install the clutch release bearing (3) to the clutch
shift fork (5).
220RW007

Transmission type Fully synchronized forward and reverse gears
Control method Direct control with the gear shift lever on the floor
Gear ratio 1st 3.954
2nd 2.330
3rd 1.436
4th 1.000
5th 0.788
Rev 3.918
Oil capacity lit (US qt) 2.7 (2.86)
Type of lubricant Engine oil : Refer to the chart in “SECTION 0”
E07RY002
E07RW030
Special Tools
TOOL NO. TOOL NO.
TOOL NAME TOOL NAME
J–42794
J–42799
Gear spline pieace
Installer
remover
J–42800
J–42795
Counter gear shaft front
Center bearing remover
bearing installer
J–42904
J–42988
Top gear shaft front
Attachment
bearing installer
J–42796 J–42801
Counter gear shaft Front rerainer oil seal
center bearing installer installer
J–42797 J–42802
Clutch hub (No.2) Transfer adapter oil seal
installer installer
J–42798
J–8092
Clutch hub (No.1)
Driver handle
installer
TOOL NO.
ILLUSTRATION
TOOL NAME
J–22912–01
Bearing separator
CLUTCH 7C–1
TROOPER
TRANSMISSION
CLUTCH
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 7C–1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–16
General Description . . . . . . . . . . . . . . . . . . . . . 7C–2 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–16
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–6 Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . 7C–19
Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . 7C–7 Inspection and Repair . . . . . . . . . . . . . . . . . . 7C–19
Clutch Assembly and Associated Parts . . . 7C–7 Slave Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–7 Disassembled View . . . . . . . . . . . . . . . . . . . . 7C–20
Inspection and Repair . . . . . . . . . . . . . . . . . . 7C–8 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–12 Inspection and Repair . . . . . . . . . . . . . . . . . . 7C–20
Clutch Control . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–15 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–21
Clutch Control Parts . . . . . . . . . . . . . . . . . . . 7C–15 Main Data and Specifications . . . . . . . . . . . . . 7C–22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–15 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C–24
Inspection and Repair . . . . . . . . . . . . . . . . . . 7C–15
Service Precaution CAUTION: Always use the correct fastner in the

proper location. When you reolace a fastener, use
RESTRAINT SYSTEM(SRS). REFER TO THE SRS ISUZU will call out those fasteners that requir a
ORDER TO DETERMINE WHETHER YOU ARE the fasteners that requir thread lockers or thread
PERFORMING SERVICE ON OR NEAR THE SRS sealant. UNLESS OTHERWISE SPECIFIED , do not
ARE PERFOMING SERVICE ON OR NEAR THE SRS corrosion inhibitors) on threaded fastners or fastner
COMPONENTS OR THE SRS WIRING, REFER TO joint interfaces. Generally,such coatings adversely
THE SRS SERVICE INFORMATION. FAILURE TO affect the fastner torque and the joint clamping force,
FOLLOW WARNINGS COULD RESULT IN POSSIBLE and may damage the fastner. When you install
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR fasteners, use the correct tightening sequence and
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. specifications. Following these instructions can
help you avoid damage to parts and systems.
7C–2 CLUTCH
General Description
Clutch
A07RW046
For 6VE1 (3.5L) engine model, the pull-type clutch is the release lever (release bearing) to disengage the
employed. The pull-type clutch is disengaged by pulling pressure plate.
CLUTCH 7C–3
Master Cylinder
A07RW007
Slave Cylinder
A07RS005
7C–4 CLUTCH
Pressure Plate Assembly
A07RS006
CLUTCH 7C–5
Driven Plate Assembly
A07RS007
7C–6 CLUTCH
Diagnosis
Dragging Fluid leakage. Repair
Air in hydraulic line. Bleed
Master cylinder and slave cylinder Replace seals.
seals worn.
Driven plate warped. Replace driven plate.
Diaphragm spring weakened or tip of Replace pressure plate
fingers worn.
Driven plate sticking on splines. Lubricate with grease or replace.
Clutch spline worn. Repair
Release bearing worn or damaged. Replace release bearing.
Slipping Driven plate facing worn or oil Replace driven plate and check for
soaked. leaks.
Diaphragm spring weakened. Replace pressure plate.
Pressure plate or flywheel warped. Correct or replace.
Master cylinder and slave cylinder Replace seals.
seals worn.
Chattering Engine mounts loose or damaged. Tighten or replace.
Driven plate facing warped. Replace driven plate.
Surface of facing hardened. Replace driven plate
Driven plate facing oil soaked. Replace driven plate and check for
leaks.
Damper springs weakened or Replace.
broken.
Pressure plate or flywheel warped. Correct or replace.
Noisy Replace bearing binding. Correct, or replace if damaged, and
lubricate.
Replace bearing worn or damaged. Replace release bearing.
Release bearing poorly lubricated. Lubricate.
Pilot bearing worn. Replace pilot bearing.
Damper springs weakened or Replace driven plate.
broken.
Rivets of driven plate exposed. Replace driven plate.
Replace driven plate. Hydraulic line blocked. Clean out or replace.
Master or slave cylinders binding. Repair or replace as needed.
CLUTCH 7C–7
Clutch Assembly
Clutch Assembly and Associated Parts
201RW018–1
Legend (4) Transmission Assembly

(1) Flywheel Assembly and Crankshaft Bearing (5) Front Cover
(2) Driven Plate Assembly (6) Shift Fork
(3) Pressure Plate Assembly (7) Release Bearing
Removal
1. Remove transmission assembly, refer to ”MANUAL
TRANSMISSION” of Section 7B for ”Removal AND
INSTALLATION” procedure.
2. Remove pressure plate assembly (2).
3. Remove driven plate assembly (1), use the pilot
aligner J-24547 to prevent the driven plate assembly
(1) from falling free.
201RW005
7C–8 CLUTCH
4. Mark the flywheel, clutch cover and pressure plate lug Inspection and Repair
for alignment when installing.
5. Remove the release bearing (3) from the damage, or any other abnormal condition are found
transmission case . through inspection.
6. Remove the shift fork snap pin.
Pressure Plate Assembly
7. Remove the shift fork pin and shift fork (4) from the
front cover.
8. Remove the front cover bolts.
9. Remove the front cover (5) from the transmission
case.
201RS002
1. Visually check the pressure plate friction surface for

excessive wear and heat cracks.
2. If excessive wear or deep heat cracks are present,
the pressure plate must be replaced.
220RW088
10. Remove flywheel assembly and crankshaft bearing, Pressure Plate Warpage
do not remove except for replacement.
11. Use the remover J–5822 and sliding hammer
J–23907 to remove the crankshaft bearing.
201RS003
015RW050
CLUTCH 7C–9
1. Use a straight edge and a feeler gauge to measure 2. Place a new driven plate over the pressure plate. A
the pressure plate friction surface flatness in four metal sheet with A thickness of 8.3 mm (0.327 in)
directions. may be used in place of the driven plate.
2. If any of the measured values exceeds the specified 3. Compress the pressure plate assembly until the
limit, the pressure plate must be replaced. distance B becomes 12 mm (0.472 in).
Pressure Plate Warpage 4. Note the pressure gauge reading.
Limit: 0.3 mm (0.012 in) 5. If the measured value is less than the specified limit,
the pressure plate assembly must be replaced.
Clutch Cover Clutch Set Force
Standard: 7208 N ( 1621 lb)
Limit: 6468 N (1454 lb)
Diaphragm Spring Finger Height
201RS004
1. Visually check the entire clutch cover for excessive

wear, cracking, and other damage.
2. The clutch cover must be replaced if any of these
conditions are present. 201RW009
Legend
Clutch Set Force
(1) Release Side
1. Place a new driven plate or a 8.3 mm (0.327 in)

spacer beneath the pressure plate.
2. Fully compress the pressure plate and diaphragm
spring.
3. There are two ways to do this.
4. Use a bench press to press down on the assembly
from the top.
5. Tighten the fixing bolts.
NOTE: Preload on diaphragm spring finger must be 49 –
98 N (11 – 22 lb) in direction of release, when clutch cover
assembly is bolted to the flywheel.
6. Measure the spring height from base to spring tip A. If
the measured value exceeds the specified limit, the
pressure plate assembly must be replaced.
Spring Finger Height
Standard: 49.9 mm – 51.9 mm (1.965 in –
201RS005
2.043 in)
1. Invert the pressure plate assembly.
7C–10 CLUTCH
Driven Plate Assembly 1. Insert the clutch pilot aligner into the driven plate
splined hub.
2. The clutch pilot aligner J-24547 must be held
perfectly horizontal.
3. Set a dial indicator to the driven plate outside
circumference.
4. Slowly turn the driven plate.
5. Read the dial indicator as you turn the driven plate.
driven plate assembly must be replaced.
Driven Plate Warpage
Limit: 1.0 mm (0.039 in)
Driven Plate Splined Hub Spline Wear
201RS007
1. Visually check the torsion spring for looseness,

breakage, and weakening.
2. If any of these conditions are discovered, the driven
plate assembly must be replaced.
3. Visually check the facing surfaces for cracking and
excessive scorching.
4. Visually inspect the facing surfaces for the presence
of oil or grease.
5. If any of these conditions are discovered, the facing
must be cleaned or replaced.
6. Check that the driven plate moves smoothly on the
transmission top gear shaft spline.
7. Minor ridges on the top gear shaft spline may be
removed with an oil stone. 201RS009
1. Clean the driven plate splined hub.

Driven Plate Warpage
2. Install the driven plate to the transmission top gear
shaft spline.
3. Set a surface gauge to the driven plate outside
circumference.
4. Slowly turn the driven plate counterclockwise.
5. Measure the spline rotation play as you turn the
driven plate.
driven plate assembly must be replaced.
Driven Plate Splined Hub Spline Wear
Limit: 1.0 mm (0.039 in)
201RS008
CLUTCH 7C–11
Rivet Head Depression 3. When replacing the release bearing, replace both the
wedge collar and wire ring at the same time.
201RS010
201RW010
1. Use a depth gauge or a straight edge with steel rule to
measure the rivet head depression 1 from the facing Legend
surface 2. (1) Wire Ring
2. Be sure to measure the rivet head depression on both (2) Pressure Plate Assembly
sides of the driven plate. (3) Wedge Collar
3. If the measured value is less than the specified limit, (4) T/M Side
the driven plate assembly must be replaced. (5) Release Bearing
Rivet Head Depression (6) Engine Side
Limit: 0.2 mm (0.008 in) Wedge Collar
Release Bearing
201RS013
1. Visually check the surfaces of the wedge collar

201RS011
making contact with the release bearing for excessive
1. Visually check the release bearing for excessive play, wear and damage.
noise and breakage. 2. Replace any exhibiting excessive wear or damage.
2. If any of these conditions are discovered, the release
bearing must be replaced.
7C–12 CLUTCH
Shift Fork 2. Install new flywheel fixing bolts in the order illustrated
and tighten them to the specified torque.
NOTE: Do not reuse the bolt and do not apply oil or thread
lock to the bolt.
201RS014
1. Visually check the surfaces of the shift fork making

contact with the release bearing for excessive wear
and damage.
2. Remove any minor stepping or abrasion from shift
015RS047
fork with an oil stone.
3. Install the front cover (5) to the transmission case.
3. Replace any exhibiting excessive wear or damage.
4. Tighten three fulcrum bridge bolts to the specified
torque.
Installation Torque: 16.5 N·m (12 lb ft)
1. Install flywheel assembly and crankshaft bearing, use
the installer J-26516-A and driver handle J-8092 to
install the crankshaft bearing then clean and lubricate
with grease.
220RW088
5. Apply molybednum disulfide type grease to the pin

hole inner circumferences and thrust surfaces.
6. Attach the shift fork to the front cover and insert the
pin from below of the front cover.
015RS046
CLUTCH 7C–13
7. Install the washer and snap pin. 9. Install the release bearing in the proper direction.
NOTE: Ensure release bearing is properly positioned
during installation, as shown in illustration.
201RW020
10. Install driven plate assembly, use the pilot aligner

J-24547 to install the driven plate assembly.
201RW019
8. Apply molybdenum disulfide type grease to the areas

201RS016
201RW012
7C–14 CLUTCH
11. Install pressure plate assembly and tighten the bolts
holding the pressure plate assembly in the order
201RS017
12. Remove the aligner.

NOTE: Do not strike the aligner with a hammer to remove
it.
13. Install transmission assembly.
CLUTCH 7C–15
Clutch Control
Clutch Control Parts
203RW001
Legend (3) Pin and Jaw Joint Pin

(1) Master Cylinder Assembly (4) Oil Line Pipe
(2) Pedal Assembly and Switch (5) Slave Cylinder Assembly and Heat Protector
Removal Inspection and Repair

1. Remove pin and jaw joint pin. Make necessary adjustments, repairs, and part
replacement if wear, damage or other problems are
2. Remove pedal assembly and switch.
3. Remove oil line pipe.
4. Remove slave cylinder assembly and heat protector.
5. Remove master cylinder assembly.
6. Remove damper cylinder assembly.
7C–16 CLUTCH
Installation
1. Install damper cylinder assembly.
2. Install master cylinder assembly.
3. Install slave cylinder assembly and heat protector.
4. Install oil line pipe.
5. Install pedal assembly and switch.
6. Install pin and jaw joint pin.
Adjustment
Clutch Pedal Adjustment
1. With clutch switch
1. Disconnect clutch switch (2) connector.
2. Loosen lock nut, then turn switch out until there is
a gap between the switch plunger and clutch
pedal.
203RW004
Legend
(3) Floor Panel
(4) Pedal Free Play
(5) Clutch Pedal Height
3. Tighten push rod lock nut.

4. With clutch switch
1. Turn the clutch switch until the switch bolt just
touches the clutch pedal arm.
203RW003
Legend
(1) Push Rod
(2) Clutch Switch
2. Loosen clutch master cylinder push rod lock nut. Turn

push rod by hand to set clutch pedal height (5) to
within specification.
Clutch pedal height (5): 217 mm – 227 mm
(8.543 in – 8.937 in)
203RW005
Legend
(6) Blacket
(7) Clutch Switch Bolt
(8) Clutch Pedal Arm
CLUTCH 7C–17
2. Adjust clutch switch by backing it out half a turn, 6. Clutch pedal engagement height inspection:
and measure the clearance (E) between the 1. Operate the parking brake lever and block the
clutch pedal arm and the clutch switch. wheels.
2. Start the engine, fully step on the clutch pedal,
and move the shift lever to 1st position.
3. With the engine idling, release the clutch pedal
slowly and measure its stroke just prior to its
clutching position.
Clutch Pedal Engagement Height (14)
MIN. 30 mm (1.18 in)
7. If the measured value exceeds the specified limit,
check the following points. Repair if necessary:
D Hydraulic circuit for fluid leakage or air in circuit.
D Clutch disc warped.
D Diaphragm spring weakened or tip of fingers worn.
D Driven plate sticking on sprines.
D Release bearing worn or damaged.
D Master cylinder and slave cylinder worn.
203RW006
Legend
(9) Back out Switch 1/2 turn
(10) Bracket
(11) Clutch Switch Bolt
(12) Lock Nut
(13) Clutch Pedal Arm
3. Lock the lock nut.

4. Connect clutch switch connector.
Clutch Switch and Clutch Pedal Clearance (E)
0.5 mm – 1.5 mm (0.020 in – 0.059 in)
5. After adjusting the clutch pedal height, push the
clutch pedal by hand rightly to check the clutch pedal
free play (4) to within specification.
Pedal Free Play (4)
5 mm – 15 mm (0.20 in – 0.59 in) 203RW007
Legend
(3) Floor Panel
(14) Clutch Pedal Engagement Height
203RW004
7C–18 CLUTCH
D Master cylinder to dash panel
D Clutch pedal to dash panel
D Master cylinder push rod to yoke
D Clutch pipe to master cylinder
D Clutch pipe to flexible hose
D Slave cylinder to case
D Slave cylinder bleeder screw
Torque: 8 N·m(69 lb in)
D Flexible hose to slave cylinder
206RW003
Bleeding Legend
1. Check the level of clutch fluid in the reservoir and (1) Slave Cylinder
replenish if necessary (2) Bleeder Screw
2. Bleeding the slave cylinder. (3) Vinyl Tube
1. Remove the rubber cap from the bleeder screw
and wipe clean the bleeder screw. Connect a vinyl
tube to the bleeder screw and insert the other end
of the vinyl tube into a transparent container.
2. Pump the clutch pedal repeatedly and hold it
depressed.
203RS005
3. Loosen the bleeder screw to release clutch fluid

with air bubbles into the container, then tighten
the bleeder screw immediately.
4. Release the clutch pedal carefully. Repeat the
above operation until air bubbles disappear from
the clutch fluid being pumped out into the
container. During the bleeding operation, keep
the clutch fluid reservoir filled to the specified
level. Reinstall the rubber cap.
CLUTCH 7C–19
Master Cylinder
208RW017

Inspect the removed parts. If there are abnormalities
such as wear, oil leak or other damage, replace the
master cylinder assembly.
NOTE: The master cylinder assembly cannot be
disassembled because of point–staked rod stopper.
7C–20 CLUTCH
Slave Cylinder
Disassembled View
206RW004
Legend (3) Piston and Piston Cup

(1) Cylinder Body (4) Boot
(2) Spring (5) Push Rod
Disassembly Cylinder Body

1. Remove boot.
2. Remove push rod.
3. Remove piston and piston cup.
4. Remove spring.
5. Remove cylinder body.

Make the necessary adjustments, repairs, and part
replacements if excessive wear or damage is discovered
during inspection.
206RS003
1. Clean the cylinder body.

2. Check the fluid return port for restrictions and clean it
if necessary.
CLUTCH 7C–21
Piston and Piston Cup Reassembly

1. Visually inspect the disassembled piston and piston To reassemble, follow the disassembly steps in the
cup for excessive wear and damage. reverse order, noting the following points:
2. Replace the inner parts with new parts shown in the 1. Before installing the parts, apply a thin coat of rubber
illustration. grease.
2. Install cup in groove in piston with the lip turned to the
front of cylinder. Use care so as not to scratch the
cylinder.
206RS004
3. Measure the clearance between slave cylinder wall

and piston.
4. If the measured value exceeds the specified limit, the 206RS006
slave cylinder assembly must be replaced.

Limit: 0.15 mm (0.0059 in)
206RS005
7C–22 CLUTCH

Type Dry single plate type with diaphragm spring
Size 275 mm (10.83 in)
Pressure plate Outside diameter 332 mm (13.07 in)
Pressure plate Clamping force 7208 N (1621 lb)
Pressure plate Spring finger height 49.9 – 51.9 mm (1.965 – 2.043 in)
Driven plate Outside diameter x inside diameter 275 × 180 mm (10.83 × 6.69 in)
Thickness Clutch disengaged 8.8 mm (0.346 in)
Thickness Clutch engaged 8.3 mm (0.327 in)
Total friction area 339 ×2 cm@ (52 ×2 in@)
Clutch control type Hydraulic
Clutch pedal free play 5 – 15 mm (0.20 –0.59 in)
Clutch pedal height 217 –227 mm (8.543 –8.937 in)
Clutch pedal stroke 152.5 –162.5 mm (6.004 –6.398 in)
E07RW032
CLUTCH 7C–23
Torque Specifications (Cont’d)
E07RX001
7C–24 CLUTCH
Special Tools
TOOL NO.
ILLUSTRATION
TOOL NAME
J-24547
Driven plate aligner
J-5822 and J-23907

Pilot bearing remover
and Sliding hammer
J-26516-A
Crankshaft pilot bearing
installer
J-8092
Driver handle
LIGHTING SYSTEM 8A–1
TROOPER
BODY AND ACCESSORIES

LIGHTING SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 8A–2 Dome Light Bulb . . . . . . . . . . . . . . . . . . . . . . . . 8A–10
Headlight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–2 Luggage Room Light Bulb . . . . . . . . . . . . . . . . 8A–11
Headlight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–11
Headlight and Associated Parts . . . . . . . . . 8A–3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–3 Courtesy Light Bulb . . . . . . . . . . . . . . . . . . . . . . 8A–11
Headlight Adjustment . . . . . . . . . . . . . . . . . . 8A–3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–11
Fog Light Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–4 Map Light Switch/Bulb . . . . . . . . . . . . . . . . . . . 8A–12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–12
Fog Light Assembly . . . . . . . . . . . . . . . . . . . . . 8A–5 Cigarette Lighter Illumination Bulb . . . . . . . . . 8A–12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–12
Fog Light Adjustment . . . . . . . . . . . . . . . . . . 8A–5 Ashtray Illumination Bulb . . . . . . . . . . . . . . . . . 8A–13
Front Side Marker Light Bulb . . . . . . . . . . . . . . 8A–5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–5 Glove Box Illumination Bulb . . . . . . . . . . . . . . . 8A–13
Parking Light Bulb . . . . . . . . . . . . . . . . . . . . . . . 8A–6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–13
Removal and Installation . . . . . . . . . . . . . . . 8A–6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–13
Taillight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–6 Vanity Mirror Illumination Bulb . . . . . . . . . . . . . 8A–14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–14
License Plate Light Bulb . . . . . . . . . . . . . . . . . . 8A–7 Starter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–14
Stoplight Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–7 Lighting Switch (Combination Switch) . . . . . . 8A–15
Removal and Installation . . . . . . . . . . . . . . . 8A–7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–15
High Mount Stoplight . . . . . . . . . . . . . . . . . . . . 8A–7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–7 Fog Light Switch . . . . . . . . . . . . . . . . . . . . . . . . 8A–16
Front Turn Signal Light Bulb . . . . . . . . . . . . . . 8A–8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–8 Stoplight Switch (W/O Cruise Control) . . . . . . 8A–17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–17
Rear Turn Signal Light Bulb . . . . . . . . . . . . . . 8A–9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–9 Brake Switch (W/Cruise Control) . . . . . . . . . . 8A–18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–18
Cornering Light Bulb . . . . . . . . . . . . . . . . . . . . . 8A–9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–9 Turn Signal Switch/Cornering Light Switch
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–9 (Combination Switch) . . . . . . . . . . . . . . . . . . . . 8A–18
Backup Light Bulb . . . . . . . . . . . . . . . . . . . . . . . 8A–10 Removal and Installation . . . . . . . . . . . . . . . 8A–18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–10 Hazard Warning Switch . . . . . . . . . . . . . . . . . . 8A–18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–18
8A–2 LIGHTING SYSTEM
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–19 Seat Heater Switch . . . . . . . . . . . . . . . . . . . . . . 8A–21
Tailgate Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–19 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–19 Key Remind Switch (Starter Switch) . . . . . . . 8A–21
Door Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–20 Removal and Installation . . . . . . . . . . . . . . 8A–21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–20 Illumination Controller . . . . . . . . . . . . . . . . . . . . 8A–22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–20 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–22
Rear Defogger Switch . . . . . . . . . . . . . . . . . . . 8A–20 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–20 Main Data and Specifications . . . . . . . . . . . . . 8A–23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A–21

systems.
Headlight Bulb
Removal
2. Disconnect the connector.
3. Remove the cap(1) while turning it counter clockwise.
4. Pull the bulb(2) out from the headlight body.
CAUTION: The halogen bulb develops a very high
temperature. Do not touch the glass portion. If any
stain is on the glass surface, It will scorch and the
glass will be damaged.
801RS007
Installation
Headlight
Headlight and Associated Parts
801RW003
Legend (5) Headlight Rim

(1) Radiator Grille (6) Headlight Bulb
(2) Front End Lower Panel (7) Rear Cover
(3) Headlight Assembly (8) Bracket
(4) Headlight (9) Front Combination Light
Removal Headlight Adjustment

1. Disconnect the battery ground cable. Preparation
2. Remove the screw and pull out the two projecting Place the unloaded vehicle on a level surface and check
portions on the fender to remove the front to see if the inflation pressure of the tires is correct, the
combination light. lenses are clean, and the battery is sufficiently charged.
3. Remove five clips and two screws to remove the Adjust the aim with the headlight tester, if necessary.
radiator grille. When adjusting, follow the procedure of the tester
4. Remove two screws to remove the front end lower manufacturer’s.
panel(2).
5. Remove two bolts and two nuts to remove the
headlight assembly (with bracket).
6. Remove the headlight bulb.
7. Remove two screws, two nuts and the spring for the
headlight aim adjustment to remove the bracket.
8. Remove four screws to remove the rear cover.
9. Remove the headlight rim.
10. Remove the headlight.
Installation
CAUTION: After installing the headlight, be sure to
adjust the headlight aim.
801RS009
Vertical adjustment Horizontal adjustment
Use a screwdriver for vertical adjustment. Use a screwdriver for horizontal adjustment.
801RW004 801RW005
Fog Light Bulb

Removal 5. Close the rear cover(1) of the case.

2. Open the rear cover(1) of the case.
3. Remove the dust cover.
4. Disconnect the bulb connector.
5. Remove the clip(3).
6. Remove the fog light bulb(2).
801RS004
801RS004
Installation
1. Install the fog light bulb(2).
2. Install the clip(3).
3. Connect the bulb connector.
4. Install the dust cover.
Fog Light Assembly

Removal CAUTION: After installing the fog light, be sure to
adjust the fog light aim.
2. Remove two nuts from the bracket.
Fog Light Adjustment
Turn the adjusting screw with a screwdriver to adjust the
4. Remove the fog light assembly(1). aim of the fog light vertically.
825RW104
801RW007
Installation
Front Side Marker Light Bulb

Removal
2. Remove the screw at the upper portion of the light
bracket and then remove the bracket from the fender.
3. Remove the front combination light assembly(1).
4. Remove the front side marker light socket(2) by
turning it counterclockwise.
5. Pull out the bulb(3) from the socket.
801RS003
Installation
Parking Light Bulb

Removal and Installation
Refer to the Front Turn Signal Light Bulb in this section.
Taillight Bulb
2. Remove three screws and release locks at two
locations to remove the rear combination light
assembly(2).
3. Remove the socket(3) by turning it counterclockwise.
4. Turn the bulb(1) counterclockwise while pushing it to
remove it from the socket.
803RS005
License Plate Light Bulb

2. Remove two screws to remove the lens(2).
803RS006
Stoplight Bulb
Refer to the Taillight Bulb in this section.
High Mount Stoplight

Removal
2. Remove the clips(2).
3. Pull out the high mount stoplight(1).
4. Remove the connector.
5. Remove the high mount stoplight.
803RS003
Installation
1. Insert the clips(1)(3) into the high mount stoplight(2).
2. Reconnect the connector.
3. Install the high mount stoplight.
803RS004
Front Turn Signal Light Bulb

2. Remove the screw at the upper portion of the light
bracket, and remove the bracket from the fender.
3. Remove the front combination light(1).
4. Remove the turn signal light socket(3) by turning it
counterclockwise.
5. Remove the bulb(2) by turning it counterclockwise
while pushing it at the same time.
801RS002
Rear Turn Signal Light Bulb

2. Remove the three screws and release the lock at two
positions.
3. Remove the rear combination light(3).
4. Remove the turn signal light socket/bulb(1) by turning
it counterclockwise.
803RS002
Cornering Light Bulb

Removal
2. Remove the screws at the upper portion of the light
bracket, and remove the bracket from the fender.
3. Remove the front combination light(1).
4. Remove the cornering light bulb socket(3) by turning
it counterclockwise.
801RS001
Installation
Backup Light Bulb

2. Remove three screws and release the lock at two
positions.
3. Remove the rear combination light(3).
4. Remove the backup light socket/bulb(1) by turning it
counterclockwise.
803RS001
Dome Light Bulb

2. Remove the lens(2) by releasing the locks at three
locations.
3. Remove the bulb(1).
805RS005
Luggage Room Light Bulb

2. Remove the lens(2) by releasing the locks at four
locations.
803RS007
Courtesy Light Bulb

2. Remove two screws to remove the lens(1).
805RS006
Map Light Switch/Bulb

2. Pull the map light body downward to release the lock.
3. Disconnect the connectors of the map light and the
sun roof switch.
4. Remove the map light switch.
5. Turn the socket counterclockwise to remove it.
6. Pull out the bulb from the socket.
805RS008
Cigarette Lighter Illumination Bulb

2. Remove eight screws to remove the instrument
cluster panel(2).
3. Turn the socket counterclockwise to remove it then
pull out the bulb(1).
826RS013
Ashtray Illumination Bulb

2. Removal eight screws to remove the instrument
cluster panel(1).
3. Remove the ashtray(5).
4. Remove four screws to remove the audio box(4).
5. Remove two screws to remove the ashtray guide(2).
6. Turn the socket counterclockwise to remove it then
pull out the bulb(3).
742RS001
Glove Box Illumination Bulb

2. Open the glove box lid, and then pull out the bulb(1).
805RS004
Vanity Mirror Illumination Bulb

2. Remove the lens(2).
743RW007
Starter Switch
Removal
2. Remove the front console assembly(1).
Refer to Instrument Panel Assembly in Body
Structure section.
3. Remove the lower cluster assembly(2).
Refer to the Instrument Panel Assembly in Body
Structure section.
4. Remove the instrument panel driver lower cover
assembly(3).
Structure section.
821RW024
5. Remove seven screws to remove the steering

cowl(6).
6. Disconnect the connector, remove the screw(4) and
then remove the starter switch(5).
1. When installing the steering cowl(10), be sure to pass
the harnesses through the route as shown in the
figure so that the starter switch harness(7), the
combination switch harness(8) and the inflator
module harness(9) will not get caught.
431RW005
Installation
To install, follow the removal steps in the reverse order
noting the following point.
431RW008
Lighting Switch (Combination Switch)

Removal
2. Remove the instrument panel driver lower cover(5).
Structure section.
3. Remove seven screws to remove the steering
cowl(4).
4. Disconnect the SDM (air bag controller) connector
located at lower of the instrument panel driver lower
cover.
5. Remove four fixing screws and disconnect the driver
inflator module connector to remove the driver
inflator module(3).
CAUTION: When carrying a live inflator module,
make sure the bag opening is pointed away from
you. In case of an accidental deployment, the bag
will then deploy with minimal chance of injury.
Never carry the inflator module by the wires or 825RS039
connector on the underside of the module.

When placing a live inflator module on a bench or
other surface, always face the bag and trim cover up,
away from the surface. This is necessary so that a
free space is provided to allow the air bag to expand
in the unlikely event of accidental deployment.
6. Remove the steering wheel(2).
Refer to the Steering Wheel in Steering section.
7. Disconnect the SRS coil assembly connector,remove
four fixing screws to remove the SRS coil
assembly(1).
8. Disconnect the lighting switch connector, remove
four fixing screws to remove the lighting switch(6).
Installation 2. Tighten the steering shaft nut to the specified torque.

To install, follow the removal steps in the reverse order, Torque: 34 N·m (25 lb ft)
noting the following points. 3. When connect the double lock type of inflator module
1. Check to see if the vehicle is in the straight driving connector, insert the connector completely and lock
condition and turn the rotary section of the SRS coil at outside.
assembly provided to the upper surface of the lighting Imperfect locking may cause malfunction of SRS
switch (combination switch) counterclockwise fully system circuit.
until it stops. 4. When installing the steering cowl(11),be sure to pass
Then from where it stops, turn it back about 3 the harnesses through the route as shown in the
rotations to set the alignment marks(7) together figure so that the starter switch harness(8), the
before installing the steering wheel. combination switch harness(9) and inflator module
harness(10) will not get caught.
825RW099
431RW014
Fog Light Switch

Removal
Structure section.
Structure section.
assembly(3).
Structure section.
821RW024
5. Remove the instrument panel cluster assembly(4). Installation
Structure section.
6. Disconnect the connector and push the lock from the 1. Push in the switch with your fingers until the switch is
back side of the instrument panel cluster assembly to locked securely.
remove the fog light switch(5).
825RW027
Stoplight Switch (W/O Cruise Control)

noting the following points.
2. Disconnect the connector(3), loosen the lock nut(1)
and then remove the stoplight switch(2) by turning it. 1. Check to see if the brake pedal has been returned by
the return spring to the specified position.
2. Turn the stoplight switch(1) clockwise until the tip of
the threaded portion of the switch contacts the pedal
arm(2).
3. Turn the switch counterclockwise until the space
between the tip of the threaded portion and the pedal
arm is 0.5 to 1.0 mm (0.02 – 0.04 in.).
310RS007
310RS006
Brake Switch (W/Cruise Control)

Removal 1. Check to see if the brake pedal has been returned by
1. Disconnect the battery ground cable. 2. Turn the switch clockwise until the tip of the threaded
2. Disconnect the connector(1), loosen the lock nut(3) portion of the brake switch contacts the pedal arm.
and then remove the brake switch(2) by turning it. 3. Turn the switch counterclockwise until the space
arm is 0.5 to 1.0 mm (0.02 – 0.04 in.).
310RW010
Installation 310RS003

Turn Signal Switch/Cornering Light Switch (Combination Switch)

Refer to the removal and installation steps of the Lighting
Switch (Combination Switch) in this section.
Hazard Warning Switch

Removal
Structure section.
Structure section.
assembly(3).
Structure section.
821RW024
5. Remove the instrument panel cluster assembly(4). Installation
Structure section.
6. Disconnect the connector and push the lock from the 1. Push in the switch with your fingers until it locks
back side of the instrument panel cluster assembly to securely.
remove the hazard warning switch(5).
825RW024
Tailgate Switch
2. Remove the screw and disconnect the connector(1)
to remove the tailgate switch(2).
683RS014
Door Switch
2. Remove the screw and disconnect the connector to
remove the door switch(1).
825RS043
Rear Defogger Switch

Removal
Structure section.
Structure section.
assembly(3).
Structure section.
821RW024
5. Remove the instrument panel cluster assembly(4).

Structure section.
6. Disconnect the connector and push the lock from the
back side of the instrument panel cluster assembly to
remove the rear defogger switch(5).
Installation
1. Push in the switch with your fingers until it locks
securely.
825RW023
Seat Heater Switch

2. Remove four fixing screws and disconnect the switch
connectors to remove the front console assembly(4). 1. Push the switch with your fingers until it locks
securely.
3. Push the lock from the back side of the front console
assembly to remove the seat heater switch(5).
825RW025
Key Remind Switch (Starter Switch)

Refer to the removal and installation on steps of the
Starter Switch in this section.
Illumination Controller
Refer to the Instrument Panel Assembly in Body 1. Push in the switch with your fingers until the switch is
Structure section. locked securely.
Structure section.
assembly(3).
Structure section.
821RW024

Structure section.
remove the illumination controller(5).
825RW026

Light and Bulb Specifications
D08RS063
Legend (9) Fog Light

(1) Dome Light (10) Map Light
(2) Luggage Room Light (11) High Mount Stoplight
(3) Courtesy Light (12) License Plate Light
(4) Meter (13) Turn Signal Light
(5) Side Marker Light (14) Backup Light
(6) Turn Signal Light/Parking Light (15) Taillight/Stoplight
(7) Cornering Light (16) Rear Combination Light
(8) Headlight
Bulb Rated Number Lens

Light Name Remarks
No. Power of Bulbs Color
Headlight 9004 65W/45W 2 White Halogen
Turn Signal Light/Parking
1157 27W/8W 2 White
Front Light
Combination
Side Marker Light 194 3.8W 2 Amber
Light
Cornering Light 1156 27W 2 White
Fog Light — 55W 2 White Halogen
Taillight/Stoplight 1157 8W/27W 2 Red
Rear
Combination Turn Signal Light 1156 27W 2 Amber
Li ht
Light Backup Light 1156 27W 2 White
High Mount Stoplight — — 50 Red LED
License Plate Light — 5W 1 White

Map Light — 5W 2 White
Dome Light — 10W 1 White
Luggage Room Light — 8W 1 White
Courtesy Light 194 3.8W 4 White
Air Conditioning Sw — 60mA 1
— 60mA 1 w/o Timer
RR Defogger Sw
— 80mA 1 w/Timer
Anti–Theft — 20mA 1 Warning box
Check Trans 74 1.4W 1 Red Meter
A/T Oil Temp 74 1.4W 1 Red Meter
Seat Heater SW — 50mA 2
Mirror Defogger Sw — 0.84W 1
Fog Light SW — 0.7W 1
Cruise Set 74 1.4W 1 Green Meter
Cruise Main 74 1.4W 1 Green Meter
Power Drive 74 1.4W 1 Amben Meter
Winter Driver 74 1.4W 1 Green Meter
Turn Signal 74 1.4W 2 Green Meter
Upshift 74 1.4W 1 Amben Meter
High Beam 74 1.4W 1 Blue Meter
ABS 74 1.4W 1 Amben Meter
Indicator /
Warning light Seat Belt 80 2W 1 Red Meter
Malfunction Indicator 74 1.4W 1 Amben Meter
(Check Engine)
Low Fuel 74 1.4W 1 Amben Meter
4WD 74 1.4W 1 Green Meter
Oil Pressure 74 1.4W 1 Red Meter
Brake System 74 1.4W 1 Red Meter
Charge 74 1.4W 1 Red Meter
A/T Shift Position 74 1.4W 7 P,N,D,3,2, Meter
L : Green
R : Amben
Air Bag 80 2W 1 Red Meter
Front–1 74 1.4W 1 Green
TOD
Rear 74 1.4W 1 Green
Auto 74 1.4W 1 Green
Check 74 1.4W 1 Red
Application N·m Lb Ft Lb In
Steering Shaft Nut 34 25 —
WIPER/WASHER SYSTEM 8B–1
TROOPER

WIPER / WASHER SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 8B–1 General Description . . . . . . . . . . . . . . . . . . . . . . 8B–7
Windshield Wiper/Washer System . . . . . . . . . 8B–2 Rear Wiper and Washer Switch . . . . . . . . . . . 8B–7
General Description . . . . . . . . . . . . . . . . . . . . . . 8B–2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–7
Windshield Wiper And Washer Switch . . . . . 8B–2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–7
Removal and Installation . . . . . . . . . . . . . . . 8B–2 Rear Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . 8B–8
Windshield Wiper Motor . . . . . . . . . . . . . . . . . . 8B–2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–2 Alarm & Relay Control Unit . . . . . . . . . . . . . . . 8B–9
Windshield Washer Motor . . . . . . . . . . . . . . . . 8B–3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–3 Rear Washer Motor . . . . . . . . . . . . . . . . . . . . . . 8B–9
Windshield Wiper Linkage . . . . . . . . . . . . . . . . 8B–4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–9
Windshield Wiper Linkage and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–9
Associated Parts . . . . . . . . . . . . . . . . . . . . . . 8B–4 Rear Wiper Arm/Blade . . . . . . . . . . . . . . . . . . . 8B–10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–10
Windshield Wiper Arm/Blade . . . . . . . . . . . . . . 8B–5 Rear Washer Nozzle . . . . . . . . . . . . . . . . . . . . . 8B–10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–10
Windshield Wiper Blade Rubber . . . . . . . . . . . 8B–6 Rear Washer Nozzle Angle Adjustment . . . 8B–10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–6 Rear Wiper Blade Rubber . . . . . . . . . . . . . . . . 8B–11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B–6 Removal and Installation . . . . . . . . . . . . . . . 8B–11
Rear Wiper/Washer System . . . . . . . . . . . . . . 8B–7 Main Data and Specifications . . . . . . . . . . . . . 8B–11

systems.
8B–2 WIPER/WASHER SYSTEM
Windshield Wiper/Washer System

General Description When the wiper & washer switch is turned on with the
starter switch on, the battery voltage is applied to the
The circuit consists of the starter switch, windshield wiper wiper motor to activate the wiper.
& washer switch, windshield wiper motor, windshield The washer motor squirts glass cleaning fluid while the
washer motor and windshield intermittent relay. washer switch is being pushed. The intermittent relay is
used to control motion of the wiper.
Windshield Wiper And Washer Switch

Refer to the Lighting Switch (Combination Switch) in
Lighting System section.
Windshield Wiper Motor

3. Remove 4 mounting bolts.
4. Remove the windshield wiper motor(1).
880RW007
Windshield Washer Motor

2. Remove the fender inner liner (right side) (1).
3. Remove the screws and then remove the front
combination light(2).
4. Remove 2 screws, the filler neck and the hose.
5. Disconnect the windshield washer motor connector
and remove the washer tank (4).
6. Pull the windshield washer motor(3) from the washer
tank(4).
880RS006
Windshield Wiper Linkage

Windshield Wiper Linkage and Associated Parts
880RW008
Legend (3) Windshield Wiper Linkage Assembly

(1) Windshield Wiper Arm/Blade (4) Windshield Wiper Motor
(2) Vent Cowl Cover
2. Remove the windshield wiper arm/blade.
3. Remove the windshield wiper motor.
4. Remove the pivot assembly mounting nuts, fixing
screws and then remove the vent cowl cover.
5. Take out the windshield wiper linkage assembly from
the opening of the cowl.
Windshield Wiper Arm/Blade

Removal D Tighten the nuts to the specified torque.
1. Pry the cap(2) off with the tip of a screwdriver. Torque: 31 N·m (23 lb ft)
2. Remove the nut(3).
3. Remove the wiper/blade(1).
880RS005
Installation
880RS004
1. Wiper arm/blade
D Before installing the wiper arm/blade to the shaft,
confirm that the motor stops at the auto-stop
position.
D Set the wiper arm/blade so that the tips of both
blades are positioned about 35 mm (1.37 in) from
the upper edge of the cowl cover as shown in the
figure.
Windshield Wiper Blade Rubber

1. Push the wiper blade lock(1) while pulling the wiper To install, follow the removal steps in the reverse order,
blade in the arrow direction as shown in the figure. noting the following points.
1. Install the click of the blade stay in the groove of the
CAUTION: When the wiper blade has been
new rubber and slide it in. Complete wiper blade
removed, wrap the tip of the wiper arm with cloth, to
installation by pushing the click.
avoid damaging the glass.
885RS002
880RS011
2. Finally, check that the click of the stay has caught in
2. Pull the end of rubber and remove the projection(3)
the hole of the rubber.
from the click of the blade stay (2).
885RS001
880RS010
3. Pull the rubber out in the same direction.

Rear Wiper/Washer System

General Description When the wiper & washer switch is turned on with the
starter switch on, the battery voltage is applied to the
The circuit consists of the starter switch, rear wiper & wiper motor to activate the wiper.
washer switch, rear wiper motor, rear washer motor and The washer motor squirts glass cleaning fluid while the
rear intermittent relay. washer switch is being pushed. The intermittent relay is
used to control motion of the wiper.
Rear Wiper and Washer Switch

Removal
Structure section.
Structure section.
Structure section.
821RW023
Installation
1. Push the switch with your fingers until it locks
securely.
821RW024

Structure section.
remove the rear wiper & washer switch(5).
Rear Wiper Motor

Removal
2. Remove the tailgate trim pad.
3. Remove the wiper arm/blade.
Refer to the removal steps of the Rear Wiper
Arm/Blade in this section.
4. Disconnect the connector remove the wiper shaft nut,
remove the fixing screws and then remove the rear
wiper motor(1).
885RS012
885RS013
Installation
1. Before installing the wiper arm/blade to the motor
shaft, confirm that the motor stops at the auto-stop
position.
2. Install the wiper arm so that the blade gets parallel to 885RS011
the lowermost heat wire(2) of the rear defogger 3. Tighten the motor shaft nut to the specified torque.
(w/rear defogger), or position the blade 20 mm
(0.79 in) from edge of tailgate glass (W/O rear
defogger). 4. Tighten the wiper arm nut to the specified torque.
Alarm & Relay Control Unit

2. Remove the glove box.
3. Remove the instrument panel passenger lower cover
assembly.
4. Remove the passenger Knee bolster reinforcement
assembly.
5. Remove the fixing bolts, disconnect the connectors
and then remove the alarm & relay control unit (1).
826RW020
Rear Washer Motor

Removal
2. Remove the tailgate trim pad(2).
3. Remove two screws, disconnect the connector,
remove the washer hose and then remove the rear
washer tank(3).
4. Pull out the rear washer motor(1) from the washer
tank.
885RS009
Installation
Rear Wiper Arm/Blade

1. Remove the arm nut(2). Refer to the installation steps of the Rear Wiper Motor in
Wiper/Washer System section.
2. Remove the wiper arm/blade(1).
885RS008
Rear Washer Nozzle

Removal Rear Washer Nozzle Angle
1. Disconnect the hose(3). Adjustment
2. Remove the lock nut(2), and then remove the washer Loosen the lock nut(2) of the washer nozzle(1) to adjust
nozzle(1). the injection angle of the cleaning fluid, and then retighten
the lock nut(2).
885RS005
885RS004
Installation
Rear Washer Spray Pattern
885RS003
Legend
(1) Washer Nozzle
(2) Spray Target
Rear Wiper Blade Rubber

Refer to the Windshield Wiper Blade Rubber in this
section.

Windshield Wiper Motor Shaft Nut 14 — 122
Windshield Wiper Arm Nuts 31 23 —
Rear Wiper Motor Shaft Nut 6 — 52
Rear Wiper Arm Nut 9 — 78
ENTERTAINMENT 8C–1
TROOPER

ENTERTAINMENT
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 8C–1 Glass Antenna Amplifier Removal . . . . . . . 8C–5
Cigarette Lighter . . . . . . . . . . . . . . . . . . . . . . . . 8C–2 Glass Antenna Amplifier Installation . . . . . . 8C–5
General Description . . . . . . . . . . . . . . . . . . . . . . 8C–2 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–6
Digital Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–2 Front Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–7
Rod Type Antenna . . . . . . . . . . . . . . . . . . . . . . 8C–3 Tweeter Assembly . . . . . . . . . . . . . . . . . . . . . . . 8C–7
Diversity Glass Antenna . . . . . . . . . . . . . . . . . . 8C–4 Rear Speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–8
Glass Antenna System Parts Location . . . . 8C–4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–8
Glass Antenna Pattern . . . . . . . . . . . . . . . . . 8C–5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C–8
Service Precaution
systems.
8C–2 ENTERTAINMENT
Cigarette Lighter
General Description
When the cigarette lighter is pushed in with the starter
switch at either “ACC” or “ON” position, a circuit is formed
in the cigarette lighter case to heat the lighter coil.
The cigarette lighter is sprung back to its original position
after the lighter coil is heated.
Removal
Refer to the Instrument Panel Assembly removal
steps in Body Structure section.
3. Disconnect the connectors, remove the socket of the
illumination light, the retaining ring(7), the outer
case(6), the cigarette lighter(3) and socket(4), the
bezel(5) and then remove the cigarette lighter
assembly(2).
826RS007
Installation
1. When installing the bezel, align the projected portion
of the socket with the notch of the bezel.
Digital Clock
Removal
Structure section.
Structure section.
assembly(3).
Structure section.
821RW024

Structure section.
6. Disconnect the connector and push the lock from the Installation
remove the digital clock(5). To install, follow the removal steps in the reverse order,
1. Push in the switch with your fingers until it locks
securely.
821RW034
Rod Type Antenna

Removal
2. Turn the antenna rod(1) counterclockwise to remove
it.
3. Remove three screws and nine clips to remove the
fender inner liner(2).
4. Disconnect the feeder cable connector at the inside of
the vehicle, remove the housing bracket screw, turn
the lock nut counterclockwise to remove it together
with the base mold and then remove the housing(3).
890RS004
Installation
Diversity Glass Antenna

Glass Antenna System Parts Location
890RW014
Legend (4) Glass Antenna Amplifier

(1) Glass Antenna (LH) (5) Connection with the audio side feeder cables at
(2) Glass Antenna Amplifier the dash side (RH)
(3) Glass Antenna (RH)
Glass Antenna Pattern
890RW016
Glass Antenna Amplifier Removal

2. Remove the luggage side trim cover.
Refer to the Interior Trim Panels removal steps in
Exterior/Interior Trim section.
3. Disconnect the connector(1)&(4), feeder cable(3)
and remove two screws to remove the glass antenna
amplifier(2).
890RW018
Glass Antenna Amplifier Installation

Radio
1. Disconnect the battery ground cable. To install, follow the removal steps in the revers order.
2. Remove the front console assembly (1).
Structure section.
3. Remove the lower cluster assembly (2).
Structure section.
assembly (3).
Structure section.
821RW024

Structure section.
6. Remove two screws and disconnect the radio
connector(5) and antenna feeder plug(6) to remove
the radio(7).
825RW039
Front Speaker
2. Pull the grille(1) to release the locks and then remove
it.
3. Remove four screws and disconnect the
connector(3) to remove the speaker(2).
890RW013
Tweeter Assembly
2. Pull the tweeter, assembly(1) to release the clips(2)
and disconnect the connector(3) to remove the
tweeter assembly.
890RW017
Rear Speaker
Removal
2. Pull the grille(1) to release the locks and then remove
it.
3. Remove four screws and disconnect the
connector(3) to remove the speaker(2).
890RW015
Installation
WIRING SYSTEM 8D–1
TROOPER

WIRING SYSTEM
CONTENTS
Fuse, Relay and Diode . . . . . . . . . . . . . . . . . . . 8D–2
Relay and Fuse Box / Fuse Box Location . 8D–2
Relay & Fuse Box . . . . . . . . . . . . . . . . . . . . . 8D–3
Fuse Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D–4
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 8D–5
8D–2 WIRING SYSTEM
Fuse, Relay and Diode
Relay and Fuse Box / Fuse Box Location
810RY00003
Legend
(1) Relay and Fuse Box
(2) Fuse Box
Relay & Fuse Box
810RY00004
Legend (22) Not Used

(1) Relay & Fuse Box (23) Cornering Relay
(2) Lighting Relay (24) Fog Light Relay
(3) Not Used (25) Fusible Link (Main)
(4) Not Used (26) Fusible Link (Key SW)
(5) Not Used (27) Fusible Link (ECM)
(6) Thermo Relay (28) Fusible Link (Condenser Fan)
(7) Not Used (29) Not Used
(8) Compressor Relay (30) Fusible Link (ABS)
(9) Horn Relay (31) Fuse F–1 (Not Used)
(10) Tail Relay (32) Fuse F–2 (20A)
(11) Not Used (33) Fuse F–3 (15A)
(12) Fuel Pump Relay (34) Fuse F–4 (15A)
(13) PCM Main Relay (35) Fuse F–5 (15A)
(14) Not Used (36) Fuse F–6 (10A)
(15) Not Used (37) Fuse F–7 (Not Used)
(16) Diode (38) Fuse F–8 (15A)
(17) Upshift Relay–1 (39) Fuse F–9 (20A)
(18) Starter Relay (40) Fuse F–10 (15A)
(19) Not Used (41) Fuse F–11 (Not Used)
(20) Not Used (42) Fuse F–12 (15A)
(21) Not Used (43) Upshift Resistor
Fuse Box
810RY00005
Legend (19) Fuse C–7 (Not Used)

(1) Fuse Box (20) Fuse C–8 (15A)
(2) Fuse C–21 (10A) (21) Fuse C–9 (15A)
(3) Flasher Unit (22) Fuse C–10 (10A)
(4) H–49 (23) Fuse C–11 (10A)
(5) Rear Defogger Relay (24) Fuse C–12 (20A)
(6) Power Window Relay (25) Fuse C–13 (10A)
(7) Heater & A/C Relay (26) Fuse C–14 (15A)
(8) Diode (Not Used) (27) Fuse C–15 (20A)
(10) Circuit Breaker C/B–2 (29) Fuse C–17 (25A)
(11) Circuit Breaker C/B–1 (Not Used) (30) Fuse C–18 (20A)
(13) Fuse C–1 (10A) (32) Fuse C–20 (10A)
(14) Fuse C–2 (15A) (33) Diode (Not Used)
(17) Fuse C–5 (15A) (36) Diode (Lighting)
(18) Fuse C–6 (10A)
Circuit Diagram
Fuse Block Circuit

Starter and Generator

PCM–1
PCM–2
Headlight and Fog Light

Illumination Light
Turn Signal Light and Hazard Warning Light

Stoplight and Rear Defogger

Dome Light, Courtesy Light, Stop Light and Luggage Room Light
Door Lock (W/ Keyless Entry)

Door Lock (W/O Keyless Entry)

Power Window
Cruise Control
ABS–1
ABS–2
A/T Shift Lock

Anti–theft W/ Keyless Entry

Windshield Wiper and Washer

Audio
Door Mirror
Meter (W/ T,O,D)

Meter (W/O T,O,D)

A/T Shift Indicator

Air Conditioning (Manual)

Air Conditioning (Auto)–1

Air Conditioning (Auto)–2

Sun Roof
Seat Heater
SRS–Air Bag
Shift on the Fly

Torque on Demand (T,O,D)

Alarm and Relay Control Unit

METER AND GAUGE 8E–1
TROOPER

METER AND GAUGE
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 8E–1 Vehicle Speed Sensor . . . . . . . . . . . . . . . . . . . 8E–11
General Description . . . . . . . . . . . . . . . . . . . . . 8E–1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–11
Meter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 8E–2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–11
General Description . . . . . . . . . . . . . . . . . . . . . . 8E–2 Fuel Tank Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–11
Layout for Meters/Gauges, Warning Lights, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–11
Indicator Lights and Illumination Lights . . . 8E–2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–11
Table for Meter/Gauge Connector Terminal Multi Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–12
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–10
Ambient Sensor . . . . . . . . . . . . . . . . . . . . . . . . . 8E–12
Warning Light Bulb, Indicator Light Bulb, Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–12
Illumination Light Bulb, A/T Indicator
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–12
Light Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–10
Main Data and Specifications . . . . . . . . . . . . . 8E–13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E–10

The circuit consists of the starter switch, meter assembly,
vehicle speed sensor, transmission switch, lighting
switch, turn signal switch, thermo unit, oil pressure unit,
Powertrain Control Module (PCM), fuel tank unit, 4WD
switch, oil pressure switch, parking brake switch, brake
fluid switch, seat belt switch, illumination controller, multi
meter and ambient sensor.
systems.
8E–2 METER AND GAUGE
Meter Assembly
General Description
The meter assembly has the speedometer, tachometer,
engine coolant temperature gauge, fuel gauge and
warning/indicator lights.In addition, the meter assembly
containing TOD (Torque on Demand) has the TOD
indicator light, or the meter assembly not containing TOD
has the voltmeter and oil pressure gauge instead of the
TOD indicator.
Layout for Meters/Gauges, Warning

Lights, Indicator Lights and
Illumination Lights
Meter Assembly W/O TOD (Front View)
825RW033
Legend (5) Oil Pressure Gauge & Fuel Gauge

(1) Voltmeter & Engine Coolant Temperature (6) Warning Light Lens
Gauge (7) Reset Knob
(2) Tachometer (8) A/T Shift Indicator
(3) Warning Light Lens (9) Warning Light Lens
(4) Speedometer
Meter Assembly W/O TOD (Rear View)
825RW038
Legend (12) Illumination Light

(10) LCD Light (13) Illumination Light
(11) Illumination Light (14) Illumination Light
Meter Assembly W/TOD (Front View)
825RW034
Legend (5) Coolant Temperature Gauge & Fuel Gauge

(1) TOD Indicator (6) Warning Light Lens
(2) Tachometer (7) Reset Knob
(3) Warning Light Lens (8) A/T Shift Indicator
(4) Speedometer (9) Warning Light Lens
Meter Assembly W/TOD (Rear View)
825RW036
Legend (12) Illumination Light

(10) LCD Light (13) Illumination Light
(11) Illumination Light (14) Illumination Light
Table for Meter/Gauge Connector Terminal Connections

Meter Assembly W/O TOD–1
825RW037
Meter Assembly W/O TOD–2

Connector No. I–9 Connector No. I–10
Terminal Function Terminal Function
1 A/T oil temp warning light 1 Turn signal indicator light (Right)
2 Seat belt warning light 2 L position (A/T)
3 Check trans warning light 3 R position (A/T)
4 Brake warning light 4 Engine coolant temperature gauge
5 Check engine warning light 5 Speedometer
6 Charge warning light 6 —
7 Lighting switch 7 —
8 Illumination controller 8 Battery (+)
9 Tachometer 9 —
10 D position (A/T) 10 —
11 — 11 P position (A/T)
12 A/T shift indicator control unit 12 N position (A/T)
13 — 13 3 position (A/T)
14 2 position (A/T) 14 High-beam indicator light (–)
15 Starter switch 15 High-beam indicator light (+)
16 Cruise set indicator light 16 ABS indicator light
17 Cruise main indicator light 17 —
18 4WD indicator light 18 Fuel warning light
19 Ground (Gauge) 19 Oil pressure gauge
20 — 20 Fuel gauge
21 Winter drive indicator light 21 —
22 Oil pressure warning light 22 —
23 —
24 Air bag warning light
25 Power drive indicator light
26 —
27 Up shift indicator light (–)
28 Turn signal indicator light (Left)
29 Up shift indicator light (+)
30 Ground (Warning)
Meter Assembly W/TOD–1
825RW035
Meter Assembly W/TOD–2

Connector No. I–9 Connector No. I–10
Terminal Function Terminal Function
1 — 1 Turn signal indicator light (Right)
2 Air bag warning light 2 L position (A/T)
3 A/T oil temp warning light 3 R position (A/T)
4 Charge warning light 4 Check engine warning light
5 Seat belt warning switch 5 Speedometer
6 Check trans warning light 6 —
7 Brake warning light 7 —
8 — 8 Battery (+)
9 Tachometer 9 Engine coolant temperature gauge
10 — 10 Ground (Warning)
11 Turn signal indicator light (Left) 11 P position (A/T)
12 A/T shift indicator control unit 12 N position (A/T)
13 2 position (A/T) 13 3 position (A/T)
14 D position (A/T) 14 High beam indicator light (–)
15 Rear (TOD) 15 High beam indicator light (+)
16 Auto (TOD) 16 ABS indicator light
17 Check (TOD) 17 —
18 Cruise set indicator light 18 Fuel warning light
19 Cruise main indicator light 19 —
20 Oil pressure warning light 20 Fuel gauge
21 Front “1” (TOD) 21 Ground (Gauge)
22 Front “2” (TOD) 22 —
23 Front “3” (TOD)
24 Lighting switch
25 Illumination controller
26 Starter switch
27 —
28 Winter drive indicator light
29 Power drive indicator light
30 —
Removal 5. Remove four fixing screws and disconnect the meter

connectors to remove the meter assembly(5).
Structure section.
Structure section.
Structure section.
825RW031
CAUTION: The removed meter assembly should be

placed upright or with its face side up.
Installation
740RS004
Warning Light Bulb, Indicator Light Bulb, Illumination Light Bulb,

A/T Indicator Light Bulb
Removal
2. Remove the meter assembly(1).
Refer to the Meter Assembly removal steps in this
section.
3. Hold the bulb socket by hand and rotate it
counterclockwise to remove the socket & bulb(2)
from the meter body.
825RW032
Installation
Vehicle Speed Sensor

2. Disconnect the connector, remove the vehicle speed
sensor body by rotating it and then remove the vehicle 1. Tighten the vehicle speed sensor to the specified
speed sensor(1). torque.
826RS009
Fuel Tank Unit

2. Remove the fuel tank(1).
Refer to the Fuel Tank removal steps in Engine
section
3. Disconnect the connectors, remove five screws and
then remove the fuel tank unit(2).
140RS006
Multi Meter
1. Disconnect the battery ground cable. To install, follow the removal steps in the revers order.
2. Remove two caps, two screws and disconnect the
connector to remove the multi meter(1).
821RW036
Ambient Sensor
Removal
2. Disconnect the connector and remove the nut to
remove the ambient sensor(1).
821RW035
Installation

Vehicle Speed Sensor Fixing 27 20 —
BODY STRUCTURE 8F–1
TROOPER

BODY STRUCTURE
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 8F–3 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–18
Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–3 Removal (No.1 – No. 2) . . . . . . . . . . . . . . . . 8F–18
General Description . . . . . . . . . . . . . . . . . . . . . . 8F–3 Removal (No. 3 — No. 6) . . . . . . . . . . . . . . . 8F–19
Frame Dimensions . . . . . . . . . . . . . . . . . . . . 8F–4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–20
General Description . . . . . . . . . . . . . . . . . . . . . 8F–5 General Description . . . . . . . . . . . . . . . . . . . . . 8F–21
Front Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–5 Body Dimension . . . . . . . . . . . . . . . . . . . . . . . . 8F–22
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–5 Instrument Panel Assembly . . . . . . . . . . . . . . . 8F–40
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–6 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–40
Front Bumper Slider Bracket . . . . . . . . . . . . . . 8F–6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–45
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–6 Cross Beam Assembly . . . . . . . . . . . . . . . . . . . 8F–46
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–6 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–46
Rear Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–46
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–47
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–7 Front Door Assembly . . . . . . . . . . . . . . . . . . . . 8F–48
Rear Bumper Slider . . . . . . . . . . . . . . . . . . . . . 8F–9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–48
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–48
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–9 Rear Door Assembly . . . . . . . . . . . . . . . . . . . . . 8F–49
General Description . . . . . . . . . . . . . . . . . . . . . 8F–10 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–49
Cowl Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–49
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–10 Door Strikers . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–50
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–11 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–50
Engine Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–11 Door Check Arm Assembly (Front & Rear) . . 8F–51
Engine Hood Hinge . . . . . . . . . . . . . . . . . . . . . . 8F–12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–52
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–12 Front Window Regulator, Glass And Glass
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–12 Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–52
Engine Hood Lock . . . . . . . . . . . . . . . . . . . . . . . 8F–13 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–52
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–13 Rear Window Regulator And Glass . . . . . . . . 8F–55
Radiator Grille And Front End Lower Panel . 8F–14 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–55
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–14 Rear Door Fixed Glass And Glass Run . . . . . 8F–57
Front Fender Panel . . . . . . . . . . . . . . . . . . . . . . 8F–16 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–57
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–16 Front Door Sash Moulding . . . . . . . . . . . . . . . . 8F–59
Body Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–59
8F–2 BODY STRUCTURE
Rear Door Moulding . . . . . . . . . . . . . . . . . . . . . 8F–60 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–76
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–60 Tailgate Sash Trim Cover . . . . . . . . . . . . . . . . . 8F–77
Front Door Waist Seal . . . . . . . . . . . . . . . . . . . 8F–61 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–77
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–61 Tailgate Outer Weatherstrip . . . . . . . . . . . . . . . 8F–78
Rear Door Waist Seal . . . . . . . . . . . . . . . . . . . . 8F–62 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–78
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–62 Tailgate Center Weatherstrip . . . . . . . . . . . . . . 8F–79
Removal and Installation . . . . . . . . . . . . . . . 8F–62 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–79
Front Door Weatherstrip . . . . . . . . . . . . . . . . . . 8F–63 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–79
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–63 Tailgate Main Weatherstrip . . . . . . . . . . . . . . . 8F–80
Rear Door Weatherstrip . . . . . . . . . . . . . . . . . . 8F–65 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–80
Removal and Installation . . . . . . . . . . . . . . . 8F–65 Spare Tire Carrier . . . . . . . . . . . . . . . . . . . . . . . 8F–81
Front Door Seal Finisher . . . . . . . . . . . . . . . . . 8F–66 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–81
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–66 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–81
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–66 Headlining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–82
Rear Door Seal Finisher . . . . . . . . . . . . . . . . . . 8F–67 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–82
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–67 Rear Air Deflector . . . . . . . . . . . . . . . . . . . . . . . 8F–84
Tailgate Assembly (LH) . . . . . . . . . . . . . . . . . . 8F–68 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–84
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–69 Roof Moulding . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–86
Tailgate Assembly (RH) . . . . . . . . . . . . . . . . . . 8F–70 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–86
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–71 Windshield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–88
Tailgate Strikers . . . . . . . . . . . . . . . . . . . . . . . . . 8F–72 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–88
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–72 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–88
Tailgate Stopper Assembly . . . . . . . . . . . . . . . 8F–72 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–89
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–72 Rear Quarter Side Glass . . . . . . . . . . . . . . . . . 8F–93
Tailgate Dove-Tail . . . . . . . . . . . . . . . . . . . . . . . 8F–73 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–93
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–73 Tailgate Glass . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–95
Tailgate Dove-Tail Striker . . . . . . . . . . . . . . . . . 8F–74 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–96
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–74 Main Data and Specifications . . . . . . . . . . . . . 8F–97
Tailgate Frame Cover (LH) . . . . . . . . . . . . . . . 8F–75 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–107
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8F–75
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–75
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F–75
Tailgate Frame Cover (RH) . . . . . . . . . . . . . . . 8F–76

systems.
Frame
General Description
Proper frame alignment is important to assure normal
vehicle life and performance of many other parts of the
vehicle. If the vehicle has been involved in a fire, collision
or has been overloaded, it is necessary to check the
frame alignment.
Frame Dimensions
501RW013
General Description frame, a slider is used to fasten the bumper fascia to the
fender panel. The bumpers can be removed by taking
This section describes how to remove and install front them out forward or backward after removing the two
and rear bumpers. Each bumper is installed with two fixing bolts on either side.
fixing bolts used on either side to fasten the backbar to the
Front Bumper
Parts Location
601RX001
Legend (8) Front Bumper Slider

(1) Front Bumper Assembly (9) Front Bumper Slider Fixing Nut
(2) Front Bumper Retainer Bolt (10) Bumper Fascia Lower Bolt
(3) Clip (11) Front Fog Light Assembly
(4) Bumper Spacer Support (12) Reinforce Assembly
(5) Back Bar Fixing Bolt (13) Reinforce Lower Bolt
(6) Front Fog Light Connector (14) Front Bumper Fixing Bolt
(7) Front Bumper Slider Fixing Clip (15) Back Bar
Removal 9. Remove front fog light assembly.

10. Remove the front bumper slider(1).
1. Remove front fog light connector.
D Remove the two clips(4) and the two nuts(3), and
2. Remove front bumper assembly fixing bolt. release the claw from the washer(2).
D Remove the two bolts from both sides of the front
bumper.
601RW009
3. Remove front bumper assembly.

601RW010
Installation
4. Remove bumper fascia lower bolts. To install, follow the removal steps in reverse order noting
the following points:
5. Remove front bumper retainer.
1. Tighten the front bumper assembly fixing bolts to the
6. Remove reinforce lower bolts. specified torque.
D Loosen the five bolts and release claws.
7. Remove reinforce assembly.
8. Remove backbar fixing bolts.
D Remove the four bolts at each backbar.
Front Bumper Slider Bracket

Removal
1. Remove the Front bumper.
D Refer to Front Bumper in this section.
2. Remove the three nuts(1) and draw out the slider
bracket(2).
601RW003
Installation
To install, follow the removal steps in reverse order.
Rear Bumper
Parts Location
690RW001
Legend (8) Rear Bumper Fascia Bracket Screws

(1) Back Bars (9) Rear Bumper Assembly
(2) Reinforce Assembly (10) Rear Bumper Side Covers
(3) Rear Bumper Slider Brackets (11) Mud Flaps
(4) Rear Step Clips (12) Rear Bumper Assembly Fixing Bolts
(5) Reinforce Lower Bolts (13) Rear Bumper Retainers
(6) Reinforce Upper Bolts (14) Clips
(7) Rear Bumper Fascia Brackets
Removal 2. Remove mud flaps.

D Remove three screws.
1. Remove rear bumper side covers.
3. Remove bumper fascia bracket screws.
4. Remove rear bumper assembly fixing bolts. 14. Remove bumper fascia brackets.
D Remove two bolts from each side. D Remove the fixing nut on the back side of the fender
panel.
Installation
To install, follow the removal steps in reverse order noting
1. Tighten the front bumper assembly fixing bolts to the
specified torque.
2. Apply chassis grease to the slider and the slider
bracket moving surface.
690RW002
5. Remove rear bumper assembly.

6. Remove rear bumper retainers.
7. Remove reinforce upper bolts.
D Remove the rear bumper retainer from each side,
and then remove two upper bolts.
8. Remove reinforce lower screws.
9. Remove clips.
10. Remove rear step clips.
11. Remove reinforce assembly.
D Pull out both ends of the bumper fascia and take out
the reinforce assembly.
12. Remove backbars.
D Remove the three bolts from each backbar.
13. Remove rear bumper slider brackets(4).
D Remove the two clips(1) and two screws(3), and
then remove claw caught in the washer(2).
690RS003
Rear Bumper Slider

Removal
1. Remove the rear bumper.
D Refer to Rear Bumper in this section.
2. Remove the three bolts (2).
3. Remove rear bumper slider (1).
690RS004
Installation
1. Apply chassis grease to the slider and the slider
bracket moving surface.
General Description Anti-corrosion materials have been applied to the interior

surfaces of some metal panels to provide rust resistance.
This section includes items of front end sheet metal that When servicing these panels, areas on which this
are attached by bolts, screws or clips and related material has been disturbed should be properly recoated
accessory components. with service-type anti-corrosion material.
Cowl Cover
Parts Location
605RW003
Legend (4) Cowl Cover Stoppers

(1) Front Wiper Arms (5) Cowl Cover Brackets
(2) Front Window Lower Molding (6) Cowl Cover
(3) Cowl Cover Seals
Removal 3. Remove front wiper arms.

D Refer to Windshield Wiper Arm/Blade in
1. Open the hood. Wiper/Washer System section.
2. Support the hood. 4. Remove front window lower molding.
5. Remove cowl cover brackets. 8. Remove cowl cover stoppers.
D Disconnect two screws each side.
6. Remove cowl cover. Installation
D Disconnect three screws. To install, follow the removal steps in reverse order.
7. Remove cowl cover seals.
Engine Hood
1. Open the hood. To install, follow the removal steps in the reverse order
2. Support the hood.
1. Tighten the engine hood fixing bolts to the specified
3. Remove windowshield washer nozzle tube.
torque.
2. Adjust the engine hood mounting gap with reference
to Body Dimension in this section.
3. Check and see if the engine hood lock operates
normally.
880RS001
4. Remove hood hinge bolts (3).

D Before removing the hinges from the Engine hood
(1), scribe a mark (2) showing location of the hinges
to facilitate installation in the original position.
610RS003

Engine Hood Hinge

Parts Location
610RW012
Legend (3) Engine Hood Hinge

(1) Hinge Fixing Bolts And Nuts (4) Engine Hood
(2) Hood End Seal (5) Cowl Cover
1. Remove cowl cover. To install, follow the removal steps in reverse order noting
D Refer to Cowl Cover in this section.
1. Tighten the hood hinge fixing bolt and nut to the
specified torque.
D Refer to Engine Hood in this section.
Torque 13 N•m (113 lb in)
3. Remove hinge fixing bolt and nut.
4. Remove engine hood hinge.
5. Remove hood end seal.
Engine Hood Lock

Parts Location
610RY001
Legend (3) Inner Liner

(1) Control Cable (4) Radiator Grille
(2) Hood Lock Control Lever (5) Engine Hood Lock Assembly
Removal
1. Remove hood lock control lever.
2. Remove inner liner.
3. Remove control cable.
D Remove the cable fixing clips from the body panel.
D Refer to Radiator Grille And Front End Lower Panel
in this section.
5. Remove engine hood lock assembly.
D Apply setting marks (1) to the hood lock assembly
and the body prior to removal.
610RS002
Installation 2. Tighten the hood lock assembly fixing bolts to the

specified torque.
the following points: Torque : 10 N•m (87 lb in)
1. Reroute the control cable to its original position, and
check and see if the lock assembly and control lever
work normally.
Radiator Grille And Front End Lower Panel

Parts Location
603RY001
Legend
(1) Radiator Grille
(2) Front End Lower Panel
Removal
1. Open the hood.
D Raise the five clips on the radiator grille and remove
two screws.
603RS002
4. Remove front end lower panel.

D Remove two fixing bolts and remove the panel from
the fender.
Installation
To install, follow the removal steps in reverse order, noting
the following point.
1. Install the radiator grille clips remaining on the body
side in the radiator grille, and then install the radiator
grille on the body.
Front Fender Panel

Parts Location
605RY001
Legend (3) Front Fender Panel

(1) Cowl Cover (4) Front Combination Lamp Assembly
(2) Front Mud Flap (5) Inner Liner
Removal 4. Remove front combination lamp assembly.

D Disconnect fixing screw and connector.
1. Open the hood.
5. Remove front mud flap.
D Disconnect three fixing screws and four clips.
3. Remove cowl cover.
6. Remove inner liner.
D Refer to Cowl Cover in this section.
7. Remove front fender panel.
D Disconnect ten fixing bolts and two nuts.
605RW001
Installation
To install, follow the removal steps in the reverse order
1. Tighten the front fender panel fixing bolts to the
specified torque.
(1) Torque : 9 N•m (78 lb in)
(2) Torque : 7 N•m (61 lb in)
Body Mounting
Parts Location
510RX001
Removal (No.1 – No. 2)

1. Remove the front bumper.
2. Jack up the vehicle by the frame.
3. Support the front side sill and rear axle with stands.
Further, support the front jack up point with a jack.
620RS001
5. Loosen the mounting bolts (No. 5-6) on either side.
6. Remove the frame side mounting and washer.
7. Gently lower the jack supporting the front axle until
the cab side mounting can be removed.
8. Remove the cab side mounting.
D Be sure to use a splice bar around the mounting to
be removed.
420RS001
501RS001
Removal (No. 3 — No. 6)

1. Remove the rear bumper.
2. Jack up the vehicle by the frame.
3. Support the rear side sill and frame stands, and
support the rear axle with a jack.
545RS001
4. Remove the mounting bolts (No. 1-4) on either side.

D No. 1 – Hold in check not to turn from the inside of
the front fender.
D No. 2 – Remove the front door sill plate and dash
side trim panel, turn over the floor carpet and hold
the bolt in check not to turn.
D No. 3 – Remove the rear door sill plate and center
pillar lower trim cover, turn over the floor carpet and
hold the bolt in check not to turn.
D No. 4 – Remove the bolt from under the frame.
620RS002
4. Remove the mounting bolts (No. 3-6) on either side.
D No. 3 — Remove the rear door sill plate and center
pillar lower-trim cover, turn over the floor carpet and
hold the bolt in check not to turn.
D No. 4, 5 and 6 — Remove the bolts from the lower
side of the frame.
5. Remove the frame side mounting and washer.
6. Gently lower the jack supporting the rear axle until the
cab side mounting can be removed.
7. Remove the cab side mounting.
D Be sure to use a splice bar around the mounting to
be removed.
D As for No. 5 and 6, remove the frame side bracket
fixing bolts after lowering the frame gently.
501RS003
510RS001
Installation
420RS002 To install, follow the removal steps in the reverse order,
1. Tighten each mounting bolt to the specified torque.
General Description
This section describes major items of the removal,
installation and servicing procedures pertaining to the
TROOPER body. Each servicing instruction is applicable
to all models of the TROOPER, unless otherwise
specifically mentioned. For those differing by specific
models from the common procedures, they are detailed
for each model.
Body Dimension
Upper Body
A10RW001
A10RY00001
A10RY00002
A10RY00007
Front Section
A10RW003
A10RW004
Room Section
A10RW016
A10RW005
A10RW006
Rear Section
A10RW007
A10RW008
Side Body
A10RW018
A10RW009
A10RW017
Window Glass
A10RW010
A10RW011
A10RW012
A10RW013
Instrument Panel Assembly

Parts Location
740RY00001
Legend (9) Glove Box

(1) Vent Duct Assembly (10) Lower Cluster Assembly
(2) Instrument Harness Assembly (11) Front Console Assembly
(3) Instrument Panel Assembly (12) Instrument Panel Driver Lower Cover
(4) Side Defroster Grille Assembly
(5) Passenger Inflator Module (13) Driver Knee Bolster Assembly
(6) Control Lever Assembly / Control Panel (14) Radio Assembly
Assembly (15) Instrument Panel Cluster Assembly
(7) Passenger Knee Bolster Reinforcement (16) Meter Assembly
Assembly (17) Front Defroster Grille
(8) Instrument Panel Passenger Lower Cover
Assembly
Removal Supplemental Restraint System (SRS) — AIR BAG in

Restraint section.
CAUTION: For precautions on installation or 1. Disconnect the battery ground cable.
removal of SRS—air bag system, refer to
2. Remove front console assembly. 5. Remove instrument panel passenger lower cover
D Remove the 4 fixing screws and disconnect the assembly.
switch connectors. D Remove the 7 fixing screws (1) and 1 clip (2).
D Remove the 3 fixing screws (1) in order to
disconnect the cigarette lighter (3) and the
illumination (2) connectors.
740RS012
6. Remove passenger knee bolster reinforcement

assembly.
D Remove the 4 fixing bolts (2) and 4 nuts (1).
740RS014

D Remove the 2 fixing screws.
740RS011
740RT024
7. Remove instrument panel driver lower cover 9. Remove front defroster grille.
assembly. D Pry 8 claws on the front side toward you side (room
D Remove the engine hood opener fixing screws. side) and raise the grille upward.
D Remove the 2 fixing screws (2), 1 fixing bolt (3), and 10. Remove instrument panel assembly.
1 clip (4). Pull out the fasteners at the 4 positions D Remove the 2 fixing bolts on the SRS adjust bracket
(1). and the cross beam under the passenger inflator
module.
CAUTION: For precautions on installation or
removal of SRS — air bag system, refer to
Supplemental RestraintSystem (SRS) — AIR BAG in
Restraint section.
740RS010
8. Remove driver knee bolster assembly.

D Remove the 6 fixing nuts.
827RS021
D Disconnect the 3 air conditioner control cables on

the unit side.
D Remove the instrument harness connectors (5
connectors on the drivers side and 3 connectors on
the passenger side), the passenger inflator module
connector, the radio antenna cable plug, and the
ground cable fixing bolt on the center bracket.
D Remove the 4 bolts (4) and the 2 nuts (3) under the
instrument panel assembly, and the upper left and
the upper right bolts (2) and the center nut (1).
740RY00026
740RS008
11. Remove passenger inflator module. 12. Remove instrument panel cluster assembly.
D From the back of the instrument panel, remove the D Remove the 5 fixing screws (2) and pull the main
4 fixing nuts (2) on the passenger inflator module (3) unit toward you and remove the clips at the 4
and the 2 fixing nuts (1) and washers on the support positions (1). Disconnect the switch connectors.
bracket (4), then disengage the 2 clips in order to
remove the passenger inflator module.
740RS007
827RS022
13. Remove meter assembly.
D Remove the 4 meter assembly fixing screws and
disconnect the meter harness connectors.
821RS034
14. Remove control lever assembly / control panel

assembly.
D Refer to Control Lever Assembly and / or Control
Cable in HVAC section.
15. Remove radio assembly.
D Remove 2 fixing screws.
16. Remove vent duct assembly.
D Remove 5 fixing screws.
17. Remove instrument harness assembly.
D Remove the 4 fixing screws, fasteners at the 4
positions and the clips at the 7 positions.
18. Remove side defroster grille.
D
NOTE: For the order of removal steps in which each
items contained in the instrument panel assembly are
removed individually, refer to the chart.
Installation
Order Of Removal/Installation Steps For Each Item
Removal Item Removal Procedure Removal Step
Front console Shift knob (M/T), Power & Winter SW (A/T), Transfer knob, Seat 1, 2
assembly heater/Miller SW conn. and 4 screws
Lower cluster 3 screws, Ciger lighter conn. and Ashtray illumination conn. 1∼3
assembly
Glove box 2 screws 4
Instrument panel 7 screws and 1 clip 1∼5
passenger lower cover
Passenger knee 4 nuts and 4 bolts 1∼6
bolster reinforcement
Instrument panel driver Engine hood opening fixing screw, 2 screws, 1 bolt, 1 clip and 1∼3, 7
lower cover fasteners at 4 positions
Driver knee bolster 6 nuts 1∼3, 7, 8
Front defroster grille Claws at 8 positions 9
Instrument panel 2 bolts (SRS adjust bracket∼ cross beam), A/C control cable (Unit 1∼10
assembly side at 3 position), Instrument harness connector (Driver side 5
position, assist side 3 position), SRS module conn., Radio antenna
jack, Earth cable, 9 bolts and 3 nuts
Passenger inflator 4 nuts (SRS module∼Instrument panel), 2 nuts 0 and 2 washers 1∼6, 11
module (SRS module∼support bracket) and 2 clips
Instrument panel 5 Screws, fastener at 4 position and each SW conn. 1∼3, 7, 12
cluster
Meter assembly 4 screws and connectors 1∼3, 7, 12, 13
A/C control panel 4 screws and connectors 1∼3, 7, 12, 14
assembly
Radio assembly 2 screws 1∼3, 15
Vent duct assembly 5 screws 1∼10, 16
Instrument harness 4 screws, fasteners at 4 position, and clips at 7 position 1∼10, 17
assembly
Side defroster grille 18
M/T = Manual Transmission

A/T = Automatic Transmission
SRS = Supplemental Restraint System
A/C = Air Conditioning
Cross Beam Assembly

Parts Location
740RT013
Legend (5) Steering Support Bracket Assembly

(1) Cross Beam Center Bracket (6) Brake Pedal Mounting Bracket Assembly
(2) Steering Column Fixing Bolts (7) Side Support Bracket Assembly (LH)
(3) Side Support Bracket Assembly (RH) (8) Cross Beam Assembly
(4) Instrument Panel Center Bracket (9) Instrument Panel Assembly
Removal
2. Remove instrument panel assembly.
D Refer to Instrument Panel Assembly in this section.
3. Remove side support bracket assembly (LH/RH).
D Remove the 4 fixing bolts on both sides.
4. Remove cross beam center bracket
D Remove 2 fixing nuts.
5. Remove instrument panel center bracket.
D Disconnect the PCM and EBCM connector.
D Remove the DERM (SRS) with 3 fixing nuts.
CAUTION: For precautions on installation or
removal of SRS — air bag system, refer to
Supplemental Restraint System (SRS) — AIR BAG in
Restraint section.
D Remove the 2 fixing nuts (upper) and the 4 fixing 740RT010
bolts (lower).
6. Remove steering column fixing bolts. 8. Remove steering support bracket assembly.
D Remove 2 fixing bolts. D Remove the 2 fixing bolts (upper side) (1) and the 3
fixing nuts (lower side) (2).
431RW007
7. Remove brake pedal mounting bracket assembly. 740RW024
D Disconnect the 2 brake pedal mounting bracket 9. Remove cross beam assembly.
assembly fixing nuts, and remove the antitheft D Disconnect the harness clips from the crossbeam
controller. assembly, and remove 2 fixing bolts on both sides
D Disconnect the brake pedal link and the brake and 2 fixing nuts in the center.
switch, and remove the 4 fixing bolts and the nuts
on the bracket. Installation
310RS011
Front Door Assembly

Parts Location
630RS001
Legend (3) Door Hinge Assembly

(1) Door Check Arm Pin (4) Hinge Bolt
(2) Front Door Assembly (5) Door Harness Connection
Removal
2. Remove door check arm pin (1).
810RS001
5. Remove front door assembly.
Installation
630RS002
3. Remove hinge bolt.
D Align the hinge bolt to the door side hinge and put a
1. Align the door fitting to the body by referring to Body
marker on it.
Dimensions in this section.
4. Remove door harness connection (2).
2. Tighten the door hinge bolts to the specified torque.
D Pull the door harness grommet out in order to
disconnect the harness connection. Torque : 34 N•m (25 lb ft)
3. Apply chassis grease to the door check arm pin and
the door hinge moving surface.
Rear Door Assembly

Parts Location
650RW002
Legend (3) Rear Door Assembly

(1) Door Check Arm Pin (4) Hinge Bolt
(2) Door Harness Connection
Removal 4. Remove hinge bolt.

D Open the front door and remove the body side hinge
1. Disconnect the battery ground cable. bolts (2).
2. Apply a setting mark on the body side hinge.
3. Remove door check arm pin (1).
650RS002
630RS002
5. Remove door harness connection (3). 6. Remove door assembly
D Pull the door harness grommet out in order to
disconnect the door harness connection. Installation
1. Align the door fitting to the body by refer to Body
Dimensions in this section.
2. Tighten the door hinge bolts to the specified torque.
3. Apply chassis grease to the check arm pin and the
door hinge moving surface.
810RS002
Door Strikers
Adjustment
632RS001
1. Loosen the striker (1) screws.

2. Tap with a plastic hammer to align.
3. Tighten the striker screws.
Door Check Arm Assembly (Front & Rear)

Parts Location
630RS003
Legend (4) Check Arm Pin Bracket

(1) Front or Rear Door (5) Check Arm Pin
(2) Door Trim Panel (6) Front or Center Pillar
(3) Check Arm Assembly
Removal
2. Remove door trim panel.
D Refer to Front / Rear Door Trim Panel in Exterior /
Interior Trim section.
3. Remove check arm pin (1).
630RS002
4. Remove check arm assembly. 1. When installing the check arm assembly, note its
D Carefully peel off the water proof sheet as much as marking to ensure using the appropriate part.
necessary, for check arm removal. 2. Tighten the check arm fixing nuts to the specified
torque.
Installation Torque : 13 N•m (113 lb in)
To install, follow the removal steps in the reverse order, 3. Apply chassis grease to the check arm pin moving
noting the following point. surface.
Front Window Regulator, Glass And Glass Run

Parts Location
631RS002
Legend (5) Window Regulator

(1) Speaker Box (6) Window Regulator with Power Window
(2) Glass Run (7) Window Regulator Motor Connector
(3) Glass (8) Door Trim Panel
(4) Rear Guide Rail (9) Waterproof Sheet
Removal 2. Remove door trim panel.

D Refer to Front Door Trim Panel in Exterior / Interior
1. Disconnect the battery ground cable. Trim section.
3. Remove speaker box.
4. Remove waterproof sheet. D Remove the glass fixing bolts from the window
regulator (2) and lower thefront side of the glass.
When the front side of the glass comes off the glass
run (3), turn the glass inside out and pull it up from its
rear side.
631RS003
D Take notice of the door harness and the grommet,

peel the waterproof sheet off the door panel
carefully.
5. Remove glass. 631RS005
D Bring the glass (1) down to the position where the 6. Remove window regulator.
fixing bolts can be seen. D Remove the window regulator fixing bolts (4) and
the rear guide rail fixing bolt (5).
D Disconnect the window regulator motor harness
connector, if equipped with power windows.
631RS004
631RS006
7. Remove glass run. 2. Set the glass into the door panel with the front side of
D Pull the glass run (6) out from the door frame the glass lowered and insert the rear side of the glass
groove. into the glass run (1). Then insert the front side of the
glass into the glass run in order to install the glass to
the glass run while raising it up along the glass run.
3. Tighten the window regulator and the glass fixing
bolts and nuts to the specified torque.
Torque : 8 N•m (69 lb in)
4. Check to see of the window regulator operates
smoothly and the glass opens and closes properly.
Install the waterproof sheet with no clearance
between the door panel and the waterproof sheet.
631RS007
8. Remove rear guide rail.
Installation
1. Apply soap and water to the door frame groove. Insert
the glass run (1) to the door frame from the A corner in
the arrow–marked directions.
Install the glass run with its wider end pointed to the
inside of the vehicle.
A10RS023
Rear Window Regulator And Glass

Parts Location
651RW012
Legend (4) Window Regulator Motor Connector

(1) Window Regulator (5) Door Trim Panel
(2) Glass (6) Waterproof Sheet
(3) Cable Fixing Clip
Removal
D Refer to Rear Door Trim Panel in Exterior / Interior
Trim section.
3. Remove waterproof sheet (1).
D Taking notice of the door harness, peel the
waterproof sheet off the door panel carefully.
651RS002
4. Remove glass. 5. Remove window regulator.
D Bring the glass down to the position where the bolt D Disconnect the regulator motor connector (4) and
can be seen. remove the window regulator cable fixing clip (3)
D Remove the sash division 2 fixing bolts (1) and then from the door panel, if model is equipped with power
remove the glass fixing bolt to remove the glass windows.
upwards. D Remove the window regulator 7 fixing bolts (2) and
pull the regulator out from the lower hole of the door
panel.
651RS003
651RW011
Installation
1. Tighten the window regulator and the glass fixing
2. Install the waterproof sheet with no clearance
between the door panel and the waterproof sheet.
651RW010
Rear Door Fixed Glass And Glass Run

Parts Location
651RS006
Legend (4) Sash Division Fixing Bolts

(1) Glass Run (5) Door Trim Panel
(2) Rear Fixed Glass (6) Waterproof Sheet
(3) Sash Division (7) Glass
Removal
3. Remove waterproof sheet.
4. Remove glass.
D Refer to Rear Window Regulator and Glass in this
section.
5. Remove glass run.
D Pull the glass run (1) out from the door frame.
651RS007
6. Remove sash division (2).
651RS008
7. Remove door fixed glass.
Installation
1. Apply soap and water to the fixed glass.
2. Apply soap and water to the door groove and insert
the glass run (3) to the frame from the corner in the
arrow-marked directions.
3. Be sure to install the glass run with its end pointed to
the inside of the vehicle.
A10RW019
Front Door Sash Moulding

Parts Location
645RS001
Legend
(1) Front Door Sash Moulding
1. Remove front door slash moulding. 1. Front door sash moulding.
D To avoid the weatherstrip (1) and pry the door sash D Assemble the edge portion (A portion) of the
moulding (2) out from the door panel. moulding so that the clearance between the
moulding and the waist seal becomes 1 mm (0.04
in).
645RS002
Rear Door Moulding

Parts Location
645RS003
Legend (2) Rear Door Corner Moulding

(1) Rear Door Side Moulding (3) Rear Door Upper Moulding
2. Remove rear door side moulding.
1. Install each moulding with no clearance between
3. Remove rear door upper moulding.
each piece of moulding.
4. Remove rear door corner moulding.
2. Assemble the edge portion (A portion) of the
D Avoiding the weatherstrip (3), pry the moulding (2) moulding so that the clearance between the rear side
out from the door frame (1). moulding and the waist seal is 1 mm (0.04 in).
645RS004
Front Door Waist Seal

Parts Location
631RS009
Legend (2) Door Mirror

(1) Nylon Washer (3) Front Door Waist Seal
2. Remove door mirror.
1. Apply soap and water to the inside of the waist seal
D Refer to Door Mirror in this section.
and align the screw hole of the waist seal to the door
3. Remove front door waist seal. panel hole, and gently tap the seal with a rubber
D Remove the fixing screw and pull out the waist seal hammer.
(1) from the door frame while prying it up. Be sure not to tap the seal hard. This may result in
deforming the seal.
631RS010
Rear Door Waist Seal

Parts Location
651RW013
Legend
(1) Rear Door Waist Seal

Refer to Front Door Waist Seal in this section.
Front Door Weatherstrip

Parts Location
631RS008
Legend (3) Weather Strip

(1) Check Arm Pin (4) Clip
(2) Bracket
Removal
1. Remove check arm pin.
2. Remove front door weatherstrip.
D Pull the weatherstrip (1) out from the door frame.
631RS011
D Carefully remove the weatherstrip (2) from the door 3. After positioning the weatherstrip (4) corner, insert
panel. the weatherstrip into the door frame groove from A
point in the arrow–marked direction.
4. Insert the weatherstrip clip (5) into the door panel up
to its base.
631RW003
Installation
1. Apply soapy water to the door frame groove, when
installing the front door weatherstrip (2).
2. Apply the sealing adhesive (3) to the upper A portion
of the door frame (1) and press it for installation after
assembling the weatherstrip (2).
631RW009
631RS013
Rear Door Weatherstrip

Parts Location
655RS001
Legend (2) Rear Door Weather Strip

(1) Check Arm Pin (3) Clip

Refer to Front Door Weatherstrip in this section.
Front Door Seal Finisher

Parts Location
635RS002
Legend
(1) Front Door Sill Plate
(2) Front Door Seal Finisher
2. Remove front door sill plate.
1. Insert the finisher (2) into the A corner and install the
3. Remove front door seal finisher (1).
finisher in the arrow–marked directions.
D Pull the finisher out from the body panel.
2. Take care not to allow the sill plate (1) to distort or twist
the finisher.
635RS003
635RS002
Rear Door Seal Finisher

Parts Location
655RS002
Legend
(1) Rear Door Sill Plate and Luggage Side Lower
Cover
(2) Rear Door Seal Finisher
2. Remove rear door sill plate and the luggage side
lower cover. 1. Insert the rear door seal finisher (2) into the A corner
and install the finisher in the arrow-marked directions.
3. Remove rear door seal finisher (1).
2. Be careful not to allow the sill plate and cover (1) to
D Pull the rear door seal finisher (1) out from the body
distort or twist the finisher.
panel.
655RS002
635RS003
Tailgate Assembly (LH)

Parts Location
681RT001
Legend (4) Tailgate Stopper Assembly

(1) Tailgate Fixing Bolt (5) Tailgate Trim Panel (LH)
(2) Tailgate Hinge (6) Tailgate Assembly (LH)
(3) Tailgate Harness Connection
Removal
2. Remove tailgate time panel (LH).
D Refer to Tailgate Trim Panel (LH) in Exterior /
3. Remove tailgate stopper assembly
4. Remove tailgate harness connection.
D Open the luggage trim panel lid and disconnect the
tailgate harness connection.
810RS003
5. Remove tailgate fixing bolts.
681RS002
6. Remove tailgate assembly (LH).

7. Remove tailgate hinge.
D Apply a setting mark (1) on the body side hinge and
remove the hinge fixing bolts.
681RW007
Installation
1. Apply chassis grease to the tailgate hinge and the
tailgate stopper moving surface.
2. Align the tailgate fitting to the body by referring to
Body Dimension in this section.
3. Tighten the hinge bolts to the specified torque.
Tailgate Assembly (RH)

Parts Location
681RS004
Legend (4) Rear Combination Light (RH)

(1) Tailgate Assembly (LH) (5) Tailgate Fixing Bolt
(2) Tailgate Trim Panel (RH) (6) Tailgate Hinge
(3) Tailgate Harness Connection
Removal
2. Remove rear combination light (RH).
3. Remove tailgate trim panel (RH).
D Refer to Tailgate Trim Panel (RH) in Exterior /
4. Remove tailgate harness connection.
D Disconnect the tailgate harness connection.
810RS004
5. Remove tailgate fixing bolt.
681RS005
6. Remove tailgate assembly (RH).

7. Remove tailgate hinge.
D Apply a setting mark (1) on the body side hinge and
remove the hinge fixing bolts.
681RW006
Installation
1. Apply chassis grease to the tailgate hinge moving
surface.
2. Align the tailgate fitting to the body. Refer to Body
Dimension in this section.
3. Tighten the hinge bolts to the specified torque.
Tailgate Strikers
Adjustment 1. Loosen the striker screws (3) (or bolts (2)).
2. Tap the striker (1) with a plastic hammer to align.
3. Tighten the striker screws (3) (or bolts (2)).
Screw Torque : 15 N•m (11 lb ft)
Bolt Torque : 12 N•m (104 lb in)
683RW012
Tailgate Stopper Assembly

Parts Location
683RS010
Legend (2) Rear Bumper

(1) Tailgate (3) Tailgate Stopper Assembly
1. Remove tailgate stopper assembly. To install, follow the removal steps in the reverse order,
nothing the following points.
D Remove the five bolts.
1. Tighten the fixing bolts to the specified torque.
2. Apply chassis grease to the stopper moving surface.
Tailgate Dove-Tail
Parts Location
683RW011
Legend (3) Tailgate Striker

(1) Dove-Tail (4) Rear Bumper
(2) Fixing Bolt (5) Tailgate (LH)
Removal
1. Remove tailgate dove-tail.
D Remove the two bolts from each side.
Installation
nothing the following points.
1. Apply chassis grease to the dove–tail (A) moving
surface.
Tailgate Dove-Tail Striker

Adjustment
683RS012
1. Loosen the striker bolts.

2. Tap with a plastic hammer to align.
D Gaps between Dove–Tail Striker (2) and bracket (1)
are 0 mm (No clearance).
683RS013
3. Tighten striker bolts.

Tailgate Frame Cover (LH)

Parts Location
684RW001
Legend (2) Washer Tube

(1) High Mount Stop Light (3) Tailgate Frame Cover
2. Remove tailgate frame cover.
1. Hit the lower A edge portion of the cover (1) to the
D Pull the tailgate frame cover (2) out.
tailgate flange.
D Disconnect the washer tube (1) at the nozzle and 2. Clearance between the frame cover and the tailgate
pull the washer tube out from the frame cover (2). panel (B portion) is 1 mm (0.04 in).
D Disconnect the rear defogger and pull the harness
from the cover.
684RS008
684RW002
Tailgate Frame Cover (RH)

Removal
1. Remove tailgate frame cover (RH).
D Pull the frame cover out from the tailgate frame.
684RS011
Installation
1. Hit the lower A edge portion (2) of the tailgate frame
cover (1).
2. Clearance between the frame cover and the tailgate
panel (B portion) is 1 mm (0.04 in).
684RS010
Tailgate Sash Trim Cover

Parts Location
684RS012
Legend
(1) Tailgate Sash Trim Cover
1. Remove tailgate sash trim cover (1). 1. Tailgate sash trim cover (1).
D Pry the tailgate trim cover retainers free from the D Insert the trim cover retainers into the tailgate hole
tailgate panel. securely so that there are no gaps between them.
684RS013
Tailgate Outer Weatherstrip

Parts Location
682RW001
Legend
(1) Tailgate Outer Weatherstrip
2. Remove tailgate outer weatherstrip (1).
1. Insert the tailgate outer weatherstrip clip into the body
D Pry the tailgate outer weatherstrip clips (2) free from
panel hole securely in order to install the tailgate outer
the body panel.
weatherstrip with the gap between the body panel
and the weatherstrip.
682RS002
Tailgate Center Weatherstrip

Parts Location
682RS003
Legend
(1) Clip
(2) Tailgate Center Weatherstrip
Removal D Clean the tailgate center weatherstrip (4) adhesive

tape (2) and the butyl seal (3) fitting position of the
1. Remove tailgate center weatherstrip. tailgate panel.
D Remove the fixing clips in order to pull the tailgate D Affix new adhesive tape and the butyl seal to the
center weatherstrip out from the tailgate panel. weatherstrip (lower side) in order to install the
tailgate center weatherstrip to the tailgate panel
Installation with no gap between them.
1. Tailgate center weatherstrip (1).

D Start assembling at the A portion.
682RS004
682RW006
Tailgate Main Weatherstrip

Parts Location
682RS005
Legend
(1) Tailgate Main Weatherstrip
Removal
1. Remove tailgate main weatherstrip.
D Pull the tailgate main weatherstrip out from the
body panel.
Installation
1. Tailgate main weatherstrip.
D Align the A and B positions to the corners of the
body panel. Install the tailgate main weatherstrip to
the body panel by gently tapping with a plastic
hammer. There should be not clearance between
the body panel the tailgate main weatherstrip.
Spare Tire Carrier

Parts Location
530RS001
Legend
(1) Spare Tire
(2) Spare Tire Carrier
1. Remove spare tire. 1. Install the spare tire carrier.
2. Remove spare tire carrier by using spare tire carrier D Tighten the carrier fixing bolts to the specified
nut wrench J–34355. torque.
2. Install the spare tire.
D Tighten the spare tire fixing bolts to the specified
torque.
530RS002
Headlining
Parts Location
666RW003
Legend (6) Sunvisors

(1) Clip (7) Map Light
(2) Interior Trim Panels (8) Sunvisor Holder
(3) Sun Roof Finisher (W/Sun Roof) (9) Rear View Mirror
(4) Headlining (10) Multi Meter
(5) Dome Light
Removal
2. Remove interior trim panels.
D Refer to the Exterior / Interior Trim section.
3. Remove dome light.
D Remove the dome light lens and the fixing screws.
D Disconnect the dome light connectors.
4. Remove multi meter (4).
D Remove two caps (2), two screws (3) and
disconnect the connector (1).
821RW241
5. Remove rear view mirror. 7. Remove sunvisors.
D Remove the rubber stopper (1). D Remove the fixing screw and turn the sunvisor
D Pry off the mirror stay cover (2) and remove 3 holder (1) to remove it.
screws. D Disconnect the vanity mirror illumination connector.
720RW004 743RS006
6. Remove map light/sun roof switch. 8. Remove sun roof finisher (W/Sun roof).
D Pry the map light clip free from the map light/sun 9. Remove headlining.
roof switch bracket and disconnect the connector. D Remove the headlining fixing clips.
Installation
1. Install the headlining so that the fixing clips will not
come off.
2. To install the sun roof finisher (3), first fit in at one
place with the head lining (2) close to the sun roof
frame complete (1), then install the entire finisher
tightly by hitting it with a plastic hammer, not allowing
it to move up.
805RS001
665RS001
Rear Air Deflector

Parts Location
667RW001
Legend (7) Rear Outer Roof Panel

(1) Rear Roof Trim Cover (8) Seal
(2) Rear Air Deflector (9) Fixing Nut
(3) Roof Rail (10) Rear Pillar Upper Reinforcement
(4) Rear Inner Roof Rail (11) Rear Outer Roof Rail
(5) Fixing Bolt (12) Roof Panel
(6) Nylon Washer (13) Grommet
1. Disconnect the battery ground cable To install, follow the removal steps in the reverse order,
2. Remove rear roof trim cover.
D Refer to Luggage Side and Quarter Upper Trim
Cover in Exterior / Interior Trim section.
3. Remove rear air deflector.
D Take notice of the grommet and the nylon washer.
1. Install the grommet (1) to the air deflector (2) drain 3. Install the air deflector (2) to the roof by referring to the
hole. specified values shown in the illustration.
667RW002 667RW003
2. Use a new nylon washer (4). Peel off the adhesive 4. Tighten the deflector fixing to the specified torque.
tape of the washer to install the nylon washer to the air Bolt Torque : 6 N•m (52 lb in)
deflector (3).
Nut Torque : 8 N•m (69 lb in)
667RW004
Roof Moulding
Parts Location
645RX002
Legend (3) Roof Moulding Clip

(1) Windshield Side Moulding Upper Clip (4) Roof End Moulding
(2) Roof Moulding
1. Disconnect the battery ground cable. 1. Install the roof moulding clip (1).
2. Remove roof moulding. D Install the clips to the specified positions on the roof
3. Remove roof end moulding. panel flange (2).
D Remove the sealing adhesive and the adhesive
tape of the roof end moulding from the panel using a
knife or scraper while you peel them off.
4. Remove roof moulding clip.
D Remove the clips.
645RW003
2. Install the roof end moulding (3).

D Clean the body panel where the roof end moulding
is installed.
D Install the roof end moulding and the rear air
deflector (2) so that the installation clearance
between them is within the specified values.
Securely fix it with the adhesive tape (4) and sealing
adhesive (5).
645RW001
3. Install the roof moulding (9).

D Assemble the windshield side moulding upper clip
(8) to the roof panel with the clip positioning rib (6)
(oblique lines portion) attached to the roof panel
flange (7). Assemble the roof moulding (9) while
you attach the front edge portion of the roof molding
to the windshield side moulding (10).
645RX001
Windshield
Parts Location
607RX001
Legend (6) Windshield Support

(1) Windshield Upper Moulding (7) Cowl Upper Rail Flange
(2) Moulding Clip (8) Windshield Wiper
(3) Windshield Side Seal (9) Front Cowl Cover
(4) Windshield Side Moulding (10) Windshield
(5) Spacer
Removal 4. Remove windshield side moulding.

D Pull the moulding out from the windshield side
1. Disconnect the battery ground cable. moulding clip.
2. Remove windshield wiper. 5. Remove windshield support.
D Refer to Windshield Wipper Arm/Blade in 6. Remove windshield side seal.
Wiper/Washer System section.
7. Remove windshield (2).
3. Remove front cowl cover.
D Use a knife or pick to make a hole in part of the
D Refer to Cowl Cover in this section. adhesive caulking material.
D Secure one end of a piece of steel piano wire (1) (0.02 Installation
inches in diameter) to a piece of wood that can serve
as a handle. 1. Install the spacer (1).
D Clean the bonding surfaces of both the windshield
and the body panel.
D When installing the spacers, align the lower side
spacer to the R stop of the body panel and the side
spacer to the end of the body panel. Be sure to
always use a new spacer.
607RS002
D Use a pair of needle nose pliers to insert the other end

of the piano wire through the adhesive caulking
material at the edge of the windshield glass.
D Secure the other end of the piano wire to another
piece of wood.
D With the aid of an assistant, carefully move the piano 607RS003
wire with a sawing motion to cut through the adhesive D Be absolutely sure to apply glass primer and body
caulking material around the entire circumference of primer to the body panel as shown in the illustration.
the windshield glass.
D Clean the remaining adhesive caulking material from
the area of the body which holds the windshield.
8. Remove windshield upper moulding.
D Taking notice of the adhesive tape, and peel the
moulding off the windshield upper portion.
9. Remove moulding clip.
10. Remove spacer.
607RW005
Legend (7) Cowl Upper Panel

(1) Front Cowl Cover (8) Body Primer
(2) Windshield Lower Moulding (9) Roof Panel
(3) The portion of the cowl upper rail flange where (10) Sealing Adhesive
sealing adhesive is additionally filled (11) Windshield Upper Moulding
(4) Apply primer to the glass and portion where (12) Moulding Clip
sealing adhesive is additionally filled (13) Front Pillar Outer Panel
(5) Windshield (14) Windshield Side Moulding
(6) Cowl Upper Rail (15) Sealing Adhesive
2. Install the moulding clip (2).

D Install new moulding clips to the fixed position of the
windshield (3).
D Always use new moulding clips (4).
607RS004
3. Install the windshield upper moulding (1).
D Peel off the adhesive tape (2) and install the
moulding to the fixed position of the windshield (3).
D Always use new upper moulding (1).
607RS005
4. Install the windshield.
607RW005
Legend (7) Cowl Upper Panel
(1) Front Cowl Cover (8) Body Primer
(2) Windshield Lower Moulding (9) Roof Panel
(3) The portion of the cowl upper rail flange where (10) Sealing Adhesive
sealing adhesive is additionally filled (11) Windshield Upper Moulding
(4) Apply primer to the glass and portion where (12) Moulding Clip
sealing adhesive is additionally filled (13) Front Pillar Outer Panel
(5) Windshield (14) Windshield Side Moulding
(6) Cowl Upper Rail (15) Sealing Adhesive
5. Install the windshield side seal. D Check that the windshield does not leak water.
6. Install the windshield support (2).
607RS007
631RS014 7. Install the windshield side moulding.

D Apply a sealing adhesive (4) to the circumference of D Insert the windshield (5) side moulding (1) into the
the windshield (5). moulding clip (2).
D Apply the sealing adhesive to the frange portion of
the cowl upper rail.
D Adjust the gap clearance of the windshield (5).
D Install the windshield to the body panel by applying
pressure to the windshield.
D Cure the adhesive at a temperature of 20~30°C
(68∼86°F) for 24 hours.
607RS008
D Take care not to damage the side moulding when

you install it.
8. Install the front cowl cover.
9. Install the windshield wiper.
Rear Quarter Side Glass

Parts Location
641RS005
Legend (5) Ventilation Assembly

(1) Rear Quarter Upper Trim Panel (6) Side Outer Panel
(2) Fastener (7) Ventilation Assembly
(3) Rear Quarter Side Glass (8) Ventilation Fixing Clip
(4) Valve Assembly (9) Rear Quarter Side
Removal
2. Remove rear quarter upper trim panel.
D Refer to Laggage Side and Quarter Upper Trim
Cover in Exterior / Interior Trim section.
3. Remove ventilation assembly.
4. Remove valve assembly.
D Refer to Ventilation Assembly in this section.
5. Remove rear quarter side glass.
D Refer to windshield in this section.
Installation
1. Install the rear quarter side glass.
D Clean the bonding surfaces of both the glass and the
body panel.
D Install the fasteners (1) to the fixed positions of the 641RS006
glass and the body panel. D Always use new fasteners.

D Be absolutely sure to apply glass primer to the side
glass.
641RS007
D Apply a sealing adhesive (1) to the glass D Check that the rear quarter side glass does not leak
circumference. water.
2. Install the valve assembly.
3. Install the ventilation assembly.
4. Install the rear quarter upper trim panel.
641RS008
D Apply PVC primer (4) to the A clip portion.

D Insert the fixing clip on the side glass into the body
panel.
D Push the side glass against the body panel and bond
them.
D Cure the adhesive at a temperature of 20~30°C
(68~86°F) for 24 hours.
Tailgate Glass
Parts Location
682RW008
Legend (4) Glass Moulding

(1) Tailgate Glass Moulding (5) Clip
(2) Tailgate Glass (6) Body Panel
(3) Tailgate Glass Clip
Removal
1. Remove battery ground cable.
2. Remove tailgate trim panel.
3. Remove tailgate sash trim cover (RH only).
4. Remove the tailgate frame cover.
D Refer to Tailgate Frame Cover (RH & LH) in this
section
5. Remove tailgate glass.
D Refer to Windshield in this section.
682RS007
6. Remove tailgate glass clip.

Installation
682RW009
Legend (4) Sealing Adhesive

(1) Glass Moulding (5) Body Panel
(2) Tailgate Glass (6) Tailgate Frame
(3) Clip
1. Install the tailgate glass clip. 2. Install the tailgate glass (2).
D Clean the bonding surfaces of both the tailgate
glass and the tailgate panel.
D Be absolutely sure to apply glass primer to the
tailgate glass and PCV primer to the glass moulding
(1).
D Apply a sealing adhesive to the circumference of
the tailgate glass as shown.
D Insert the clip of the tailgate glass A portion into the
tailgate panel hole to position the glass.
D Install the new tailgate glass clip to the clip of the
tailgate glass B portion while sliding it, and bond the
glass to the tailgate panel by applying pressure.
Always use new tailgate glass clips.
D Cure the bonding at a temperature of 20~30°C
(68∼86°F) for 24 hours.
D Check that the tailgate glass does not leak water.
682RS008

E10RW001
E10RW002
E10RX004
E10RX005
E10RW005
E10RW001
E10RX001
E10RX002
E10RX003
E10RS010
Special Tools
TOOL NO.
ILLUSTRATION
TOOL NAME
J–34355
Spare Tire Carrier Nut
Wrench
SEATS 8G–1
TROOPER

SEATS
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 8G–1 General Description . . . . . . . . . . . . . . . . . . . . . 8G–11
Front Seat Assembly . . . . . . . . . . . . . . . . . . . . 8G–2 Seat Heater Switch Removal and
Front Seat Assembly and Associated Parts 8G–2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–2 Heat Unit Parts Location . . . . . . . . . . . . . . . . 8G–11
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–2 Heat Unit Removal and Installation . . . . . . 8G–11
Disassembled View . . . . . . . . . . . . . . . . . . . . 8G–3 Rear Seat Assembly . . . . . . . . . . . . . . . . . . . . . 8G–12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–4 Rear Seat Assembly and Associated Parts 8G–12
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–12
Power Seat Assembly . . . . . . . . . . . . . . . . . . . 8G–6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–12
General Description . . . . . . . . . . . . . . . . . . . . . 8G–6 Disassembled View (Split Type) . . . . . . . . . 8G–13
Disassembled View . . . . . . . . . . . . . . . . . . . . 8G–6 Disassembly (Split Type) . . . . . . . . . . . . . . . 8G–14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–7 Reassembly (Split Type) . . . . . . . . . . . . . . . . 8G–15
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–9 Disassembled View (Bench Type) . . . . . . . 8G–16
Power Seat Switch . . . . . . . . . . . . . . . . . . . . . . 8G–9 Disassembly (Bench Type) . . . . . . . . . . . . . 8G–17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–9 Reassembly (Bench Type) . . . . . . . . . . . . . . 8G–18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–9 Rear Seat Foot Rest . . . . . . . . . . . . . . . . . . . . . 8G–18
Front Tilt Motor / Rear Tilt Motor / Slide Motor Rear Seat Foot Rest and Associated Parts 8G–18
/ Recliner Motor . . . . . . . . . . . . . . . . . . . . . . . . 8G–10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–19
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8G–10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G–19
Removal and Installation . . . . . . . . . . . . . . . 8G–10 Main Data and Specifications . . . . . . . . . . . . . 8G–19
Seat Heater System . . . . . . . . . . . . . . . . . . . . . 8G–11

systems.
8G–2 SEATS
Front Seat Assembly

Front Seat Assembly and Associated Parts
750RY002
Legend (4) Rear Seat Foot Rest

(1) Rear Cover (5) Door Sill Plate
(2) Front Seat Assembly (6) Riser Cover
(3) Seat Belt Warning Connector (7) Front Cover
Removal 6. Remove the riser cover.

7. Remove the seat belt warning connector (Driver’s
1. Disconnect the battery ground cable. side only).
2. Remove the front cover. 8. Remove the front seat assembly.
3. Remove the rear cover. D Disconnect the power seat connector, if this model
D Remove the cover fixing screw from the rear inner is equipped with the power seats.
cover, if this model is equipped with the power
seats.
4. Remove the door sill plate. Installation
5. Remove the rear seat foot rest. To install, follow the removal steps in the reverse order,
D Refer to the Rear Seat Foot Rest in this section.
SEATS 8G–3
1. Tighten the front seat assembly fixing bolts to the 2. Install the longest bolt to the rear inner side fixing
specified torque. location, if this model is equipped with power seats.
Disassembled View
750RW003
Legend (13) Frame Assembly

(1) Spring Washer (14) Pad Assembly
(2) Head Rest (15) Trim Cover
(3) Seat Back Assembly (16) Spacer (W/O Height Adjuster)
(4) Back Board Assembly (17) Release Wire
(5) Reclining Device (18) Seat Adjuster
(6) Trim Cover (19) Seat Belt Knuckle Assembly
(7) Guide Holder (20) Height Adjuster
(8) Pad & Frame Assembly (21) Seat Cushion Assembly
(9) Slide Cover (22) Hinge Cover
(10) Reclining Knob (23) Pad & Frame Assembly
(11) Dial (W/Height Adjuster) (24) Trim Cover
(12) Lock Spring (25) Armrest Assembly
8G–4 SEATS
Disassembly 6. Remove the trim cover.

7. Remove the pad and frame assembly.
1. Remove the head rest.
8. Remove the hinge cover.
2. Remove the reclining knob.
9. Remove the back board assembly(3).
3. Remove the dial(1) (W/height adjuster).
D Pull out the back board while prying the clip of the
D Remove the side cover fixing screws and the dial back board free from the seat back assembly.
lock spring(2).
750RS005
750RW025
10. Remove the reclining device.
4. Remove the side cover.
D Turn up the seat back trim cover in order to remove
5. Remove the armrest assembly. the reclining device fixing bolts.
D Open the armrest fastener and remove the armrest
fixing bolt.
750RS006
750RS004
SEATS 8G–5
11. Remove the seat back assembly. D Remove the seat belt buckle assembly.
D Remove the seat back assembly fixing nut on the 16. Remove the height adjuster.
opposite side of the reclining device. 17. Remove the spacer (W/O height adjuster).
18. Remove the seat cushion assembly.
19. Remove the trim cover.
D Remove the trim cover hog rings from the back side
of the seat cushion assembly.
D With close attention paid to the hog rings and the
wire which connect the trim cover and the pad and
frame assembly, remove the trim cover while
turning it up.
20. Remove the frame assembly.
21. Remove the pad assembly.
Reassembly
To reassembly, follow the disassembly steps in the
reverse order, noting the following points.
1. Tighten the armrest assembly fixing bolts to the
specified torque.
750RS007 Torque: 18 N·m (13 lb ft)
12. Remove the guide holder. 2. Tighten the reclining device fixing bolts to the
D Pull the guide holder out by holding the bottom end specified torque.
of it from the seat back assembly. Torque: 47 N·m (35 lb ft)
D Remove the trim cover hog rings from the back side
of the seat back.
turning it up.
14. Remove the pad and frame assembly.
15. Remove the seat adjuster.
D Disconnect the release wire(4) and remove the
fixing bolts.
750RW006
8G–6 SEATS
Power Seat Assembly

General Description The power seat switch has a tilt & slide switch and a
recliner switch.
The circuit consists of the power seat switch, front tilt The motor built in the seat can be actuated by operating
motor (driver’s seat only), rear tilt motor (driver’s seat these switches to move the seat to desired position,
only), slide motor and the recliner motor. independent of the position of the starter switch.
Disassembled View
750RS011
Legend (11) Outer Lower Cover

(1) Reclining Device (12) Adjuster Assembly
(2) Inner Cover (13) Seat Cushion Assembly
(3) Rear Cover (14) Connecting Shaft
(4) Armrest Assembly (15) Outer Cover Fixing Screws
(5) Inner Lower Cover (16) Switch Assembly
(6) Pad & Frame Assembly (17) Outer Cover
(7) Trim Cover (18) Switch Knob
(8) Front Lower Cover (19) Outer Cover Cap
(9) Front Cover (20) Back Board Assembly
(10) Power Seat Harness (21) Guide Holder
SEATS 8G–7
(22) Trim Cover (27) Trim Cover
(23) Pad Assembly (28) Seat Heater
(24) Seat Heater (29) Frame Assembly
(25) Frame Assembly (30) Head Rest
(26) Pad Assembly (31) Seat Back Assembly
Disassembly
2. Remove the head rest.
3. Remove the switch knob.
D Pull the switch knob out.
4. Remove the outer cover cap.
5. Remove the outer cover fixing screws.
D Pull up the outer cover(1) to remove the cover from
the reclining device(2).
750RS004

13. Remove the pad & frame assembly.
14. Remove the inner cover
D Remove the cover fixing screw.
D Pull up the inner cover to remove the cover from the
reclining device(3).
750RS012
6. Remove the front cover.

7. Remove the front lower cover.
8. Remove the rear cover.
9. Remove the outer cover.
D Disconnect the switch connectors and remove the
harness fixing clips.
10. Remove the switch assembly.
D Remove the switch fixing screws from the outer
cover.
11. Remove the armrest assembly.
D Open the armrest fastener and remove the fixing
bolt.
750RW007
8G–8 SEATS
15. Remove the back board assembly(4).
D Remove the board fixing screws.
D Pull the back board downward and remove the
board from the seat back frame(5).
750RW009
17. Remove the seat back assembly.

18. Remove the guide holder(8).
D Remove the trim cover fixing hog rings(9) from the
backside of the seat back assembly.
D Hold the tip end of the guide holder and pull the
holder out from the seat back assembly.
750RW008
16. Remove the reclining device(7).

D Remove the device lower side fixing bolt in order to
separate the seat back from the seat cushion.
D Disconnect the seat heater connector.
D Remove the trim cover(6) hog rings from the
backside of the seat back assembly.
D Turn up the seat back trim cover to remove the
reclining device upper side fixing bolt.
D Disconnect the connecting shaft and the reclining
750RW010
device connectors.
D Remove the trim cover hog rings from the backside
of the seat back.
wire which connect the trim cover and pad & frame
assembly, remove the trim cover while turning it up.
20. Remove the seat heater.
23. Remove the outer lower cover.
24. Remove the inner lower cover.
25. Remove the adjuster assembly.
D Disconnect the connectors and remove the fixing
bolts.
SEATS 8G–9
D Remove the power seat harness from the adjuster 28. Remove the seat heater.
assembly. 29. Remove the frame assembly.
26. Remove the seat cushion assembly. 30. Remove the pad assembly.
D Remove the trim cover hog rings from the backside Reassembly
of the seat cushion assembly.
To reassemble, follow the disassembly steps in the
D With close attention paid to the hog rings and the reverse order, noting the following point.
wire which connect the trim cover and the pad &
turning it up. D Refer to the Torque Specifications in this section.
Power Seat Switch

1. Remove the side cover(3). To install, follow the removal steps in the reverse order.
D Refer to the Power Seat Assembly in this section.
2. Remove the tilt & slide switch lever(4).
D Hold the switch lever with your fingers and pull it
toward you.
3. Remove the tilt & slide switch(2).
D Remove two screws.
4. Remove the recliner switch(1).
D Remove two screws.
750RS025
8G–10 SEATS
Front Tilt Motor / Rear Tilt Motor / Slide Motor / Recliner Motor
Parts Location Removal and Installation
Refer to the Power Seat Assembly in this section.
750RS027
Legend
(1) Tilt Motor
(2) Slide Motor
(3) Tilt Motor
750RS028
Legend
(4) Recliner Motor
SEATS 8G–11
Seat Heater System

General Description
The circuit consists of the starter switch, seat heater
switch and the heat unit.
The seat heater is provided in driver’s and front
passenger seats (as option).
When the seat heater switch is ON, the seat heat built in
the seat back and cushion is switched on to warm the
seats.
To prevent the seats from being overheated, the circuit is
fitted with a thermostat.
Seat Heater Switch Removal and

Installation
Refer to the Seat Heater Switch in Lighting System
section.
Heat Unit Parts Location

750RS019
Legend
(2) Heat Unit (Seat Cushion Side)
Heat Unit Removal and Installation

Refer to the Power Seat Assembly in this section.
750RS018
Legend
(1) Heat Unit (Seat Back Side)
8G–12 SEATS
Rear Seat Assembly

Rear Seat Assembly and Associated Parts
755RW016
Legend (2) Rear Seat Assembly

(1) Fixing Bolts (3) Mounting Bracket Cover
Removal 4. Remove the rear seat assembly.
1. Unlock the rear seat(1) lock to remove it.

2. Remove the mounting bracket cover. Installation
3. Remove the fixing bolts. To install, follow the removal steps in the reverse order,
1. Tighten the rear seat fixing bolts to the specified
torque.
755RS002
SEATS 8G–13
Disassembled View (Split Type)
755RW020
Legend (16) Linkage Bush

(1) Free Hinge Cover (17) Device Cover
(2) Back Board (18) Trim Cover
(3) Seat Back Assembly (19) Seat Lock Cover
(4) Armrest Assembly (20) Rear Seat Belt Buckle and Lock Assembly
(5) Bush (21) Frame Assembly
(6) Armrest Set Bracket (22) Stopper Rubber
(7) Clip (23) Spring Collar
(8) Armrest Board (24) Return Spring
(9) Pillow Assembly (25) Mounting Bracket
(10) Band Hook Cover (26) Pad Assembly
(11) Trim Cover (27) Reclining Device
(12) Pad & Frame Assembly (28) Seat Cushion Assembly
(13) Release Knob (29) Linkage Bush
(14) Connecting Shaft (30) Bush
(15) Release Rod
8G–14 SEATS
Disassembly (Split Type)

1. Remove the back board.
D Remove the clips and the back board.
2. Remove the device cover.
3. Remove the release knob.
D Turn the knob counterclockwise to remove it.
4. Remove the release rod.
D Disconnect the rod from the linkage bush.
755RS017
10. Remove the armrest assembly.

D Turn up the seat back trim cover and remove the
fixing nuts.
11. Remove the armrest set bracket.
12. Remove the armrest board.
D Remove the trim cover fixing hog rings from the
backside of the seat back.
755RS004
6. Remove the connecting shaft. frame assembly, remove the trim cover while
turning it up.
7. Remove the seat back assembly.
8. Remove the band hook cover.
9. Remove the pillow assembly.
16. Remove the seat lock cover.
D Turn up the seat back trim cover and slit the pad
from the back around to the place where the lock 17. Remove the rear seat belt buckle and lock assembly.
spring(2) of the guide bush(1) is. 18. Remove the mounting bracket.
Then insert a finger through the slit and pull out the 19. Remove the return spring.
pillow while you are pressing down on the lock spring. 20. Remove the spring collar.
D Remove the hog rings and pull the trim cover out
from the frame assembly groove.
wire which connect the trim cover and the pad &
turning it up.
24. Remove the stopper rubber.
SEATS 8G–15
Reassembly (Split Type)

1. Tighten the reclining device fixing bolts to the
specified torque.
2. Loosen the rubber stopper lock nut(1). Adjust the
stopper(3) so there is no clearance between the
bottom of the stopper and the carpet(2) while you
make sure the rear seat is firmly locked.
Then tighten the lock nut securely.
755RS005
8G–16 SEATS
Disassembled View (Bench Type)
755RW021
Legend (11) Connecting Shaft

(1) Trim Cover (12) Seat Cushion Assembly
(2) Pillow Assembly (13) Connecting Link
(3) Band Hook Cover (14) Seat Lock Cover
(4) Pad & Frame Assembly (15) Rear Seat Belt Buckle and Lock Assembly
(5) Seat Back Assembly (16) Trim Cover
(6) Release Knob (17) Stopper Rubber
(7) Release Rod (18) Mounting Bracket
(8) Device Cover (19) Frame Assembly
(9) Linkage Bush (20) Pad Assembly
(10) Reclining Device
SEATS 8G–17
Disassembly (Bench Type) 9. Remove the trim cover.

D Open the fastener(3), and with close attention paid
1. Remove the device cover. to the hog rings and wire which connect the trim
2. Remove the release knob. cover and the pad and frame assembly, remove the
D Turn the knob to the counterclockwise to remove it. trim cover as you turn it up.
3. Remove the release rod.
D Disconnect the rod from the linkage bush.
750RW011

755RS004
12. Remove the seat lock cover.
5. Remove the connecting shaft. 13. Remove the rear seat belt buckle and lock assembly.
6. Remove the seat back assembly. 14. Remove the mounting bracket.
7. Remove the band hook cover. 15. Remove the trim cover.
8. Remove the pillow assembly. D Remove the hog rings and pull the trim cover out
D Refer to the Disassembly (Split Type) in this from the frame assembly groove.
section. D With close attention paid to the hog rings and the
turning it up.
18. Remove the stopper rubber.
755RS017
8G–18 SEATS
Reassembly (Bench Type)

1. Tighten the reclining device fixing bolts to the
specified torque.
2. Loosen the rubber stopper lock nut(1) and adjust the
stopper rubber(3) so there is no clearance between
the bottom of the stopper and the carpet(2), while
ensuring the rear seat is firmly locked.
Tighten the lock nut securely.
755RS005
Rear Seat Foot Rest

Rear Seat Foot Rest and Associated Parts
676RY001
Legend (3) Rear Seat Foot Rest

(1) Fixing Nut (4) Foot Rest Pad
(2) Front Seat
SEATS 8G–19
Removal 2. Remove the fixing nut.

3. Remove the rear seat foot rest.
1. Remove the foot rest pad.
Installation
676RS002

E10RW007
8G–20 SEATS
E10RW008
SECURITY AND LOCKS 8H–1
TROOPER

SECURITY AND LOCKS
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 8H–2 Tailgate Inside Lock Knob . . . . . . . . . . . . . . . . 8H–16
Front Door Lock Assembly . . . . . . . . . . . . . . . 8H–2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–16
Front Door Lock Assembly and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–16
Associated Parts . . . . . . . . . . . . . . . . . . . . . . 8H–2 Tailgate Outside Handle and/or Tailgate
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–2 Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–3 Tailgate Outside Handle and/or Tailgate
Front Outside Handle and Door Lock Cylinder 8H–4 Lock Cylinder and Associated Parts . . . . . 8H–17
Front Outside Handle, Door Lock Cylinder Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–17
and Associated Parts . . . . . . . . . . . . . . . . . . 8H–4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–4 Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–6 Key Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–19
Rear Door Lock Assembly . . . . . . . . . . . . . . . . 8H–7 Key Styles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–19
Rear Door Lock Assembly and Associated Power Door Lock System . . . . . . . . . . . . . . . . 8H–20
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–7 General Description . . . . . . . . . . . . . . . . . . . . . 8H–20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–7 Front Door Lock Actuator Removal . . . . . . 8H–20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–8 Front Door Lock Actuator Installation . . . . . 8H–20
Rear Outside Handle . . . . . . . . . . . . . . . . . . . . 8H–9 Rear Door Lock Actuator Removal . . . . . . . 8H–20
Rear Outside Handle and Associated Parts 8H–9 Rear Door Lock Actuator Installation . . . . . 8H–21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–9 Tailgate Lock Actuator Removal . . . . . . . . . 8H–21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–10 Tailgate Lock Actuator Installation . . . . . . . 8H–21
Rear Door Inside Lock Knob Link . . . . . . . . . . 8H–10 Anti-theft System . . . . . . . . . . . . . . . . . . . . . . . . 8H–22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–10 General Description . . . . . . . . . . . . . . . . . . . . . 8H–22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–10 Anti-theft & Keyless Entry Control Unit
Door Inside Lock Knob . . . . . . . . . . . . . . . . . . . 8H–11 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–11 Anti-theft & Keyless Entry Control Unit
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–22
Anti-theft Indicator Removal . . . . . . . . . . . . . 8H–22
Door Inside Handle . . . . . . . . . . . . . . . . . . . . . . 8H–11
Anti-theft Indicator Installation . . . . . . . . . . . 8H–23
Removal and Installation . . . . . . . . . . . . . . . 8H–11
Anti-theft Horn Removal . . . . . . . . . . . . . . . . 8H–23
Tailgate Lock Assembly (LH) . . . . . . . . . . . . . . 8H–12
Anti-Theft Horn Installation . . . . . . . . . . . . . . 8H–23
Tailgate Lock Assembly (LH) and
Engine Hood Switch Removal . . . . . . . . . . . 8H–23
Associated Parts . . . . . . . . . . . . . . . . . . . . . . 8H–12
Engine Hood Switch Installation . . . . . . . . . 8H–23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–13 Keyless Entry System . . . . . . . . . . . . . . . . . . . . 8H–24
ID Code Registration . . . . . . . . . . . . . . . . . . . 8H–24
Tailgate Lock Assembly (RH) . . . . . . . . . . . . . 8H–14
Anti–theft & Keyless Entry Control Unit
Tailgate Lock Assembly (RH) and
/Transmitter Replacement . . . . . . . . . . . . . . 8H–26
Associated Parts . . . . . . . . . . . . . . . . . . . . . . 8H–14
Main Data and Specifications . . . . . . . . . . . . . 8H–27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H–15
8H–2 SECURITY AND LOCKS

systems.
Front Door Lock Assembly

Front Door Lock Assembly and Associated Parts
632RS003
Legend (4) Rear Guide Rail

(1) Door Trim Panel (5) Door Lock Assembly
(2) Waterproof Sheet (6) Door Lock Switch Connector (W/Power Door
(3) To Outside Handle Lock)
Removal 3. Remove the waterproof sheet.

D Refer to the Front Window Regulator, Glass And
1. Disconnect the battery ground cable. Glass Run in Body Structure section.
2. Remove the door trim panel.
4. Raise the glass up to the uppermost position, and
then remove the rear guide rail.
5. Disconnect the door lock switch connector (w/power
door lock) and locking links (arrow marks positions),
then remove the door lock assembly fixing screws
and door lock assembly.
632RS004
Legend
(1) To Inside Lock Knob
(2) Door Lock Assembly
(3) To Actuator
(4) Door Lock Switch Connector
(5) To Inside Handle
(6) Outside Handle
Installation
1. Apply chassis grease to the lock assembly and striker
moving surface.
2. Tighten the door lock assembly fixing screws to the
specified torque.
3. Check that the door lock operates smoothly.
Front Outside Handle and Door Lock Cylinder

Front Outside Handle, Door Lock Cylinder and Associated Parts
632RS006
Legend (4) Door Lock Cylinder

(1) Door Trim Panel (5) Clip
(2) Waterproof Sheet (6) Key Switch (W/Anti-Theft)
(3) Outside Handle
Removal
3. Remove the waterproof sheet.
D Refer to the Front Window Regulator, Glass And
Glass Run in Body Structure section.
4. Disconnect the locking links (arrow marks positions) 5. Remove the key Switch.
and key switch connector (w/anti-theft) to remove the
outside handle.
632RS007
Legend
632RS005
(1) Outside Handle
Legend (2) Lock Cylinder
(1) Outside Handle (3) Key Switch
(2) To Door Lock Assembly
(3) Key Switch Connector 6. Remove the fixing clip(1) to remove the door lock
cylinder(2).
632RS009
Installation
1. Be sure to install the door lock cylinder(2) at a right
angle to the outside handle(1).
632RS008
2. For the anti-theft system, be sure to install the push

rod(3) of key switch while pressing it to the door lock
cylinder(5) so that there is no continuity between the
key switch(4) side connector terminal No. D6–2 and
D6–4 (No. D16–2 and D16–4: passenger side).
632RS010
3. Tighten the outside handle and key switch fixing bolts

4. Check for smooth outside handle and lock cylinder
operation.
Rear Door Lock Assembly

Rear Door Lock Assembly and Associated Parts
652RS001
Legend (2) Waterproof Sheet

(1) Door Trim Panel (3) Door Lock Assembly
Removal
D Refer to the Rear Window Regulator And Glass in
Body Structure section.
4. Disconnect the locking links (arrow marks positions)
and remove the fixing screws to remove the door lock
assembly.
652RS002
Legend
(1) Outside Handle
(3) To Inside Handle
(4) To Actuator
Installation
moving surface.
2. Tighten the door lock assembly fixing screws to the
specified torque.
3. Check that the door lock operates smoothly.
Rear Outside Handle

Rear Outside Handle and Associated Parts
652RS004

(1) Door Trim Panel (3) Outside Handle
Removal
4. Disconnect the locking link (arrow mark position) and
remove three fixing bolts to remove the outside
handle.
652RS003
Installation 1. Tighten the outside handle fixing bolts to the specified

torque.
noting the following points. Torque: 9 N·m (78 lb in)
2. Check that the outside handle operates smoothly.
Rear Door Inside Lock Knob Link

2. Remove the door trim panel(3).
3. Remove the waterproof sheet(2).
4. Remove the fixing screw(4) and disconnect the
locking link at the door lock assembly to remove the
rear door inside lock knob link(1).
635RS013
Door Inside Lock Knob

D Refer to the Front / Rear Door Trim Panel in
3. Turn the door inside lock knob counterclockwise and
then remove the door inside lock knob (2).
632RS011
Door Inside Handle

D Refer to the Front/Rear Door Trim Panel in
635RS008
Tailgate Lock Assembly (LH)

Tailgate Lock Assembly (LH) and
Associated Parts
684RW004

(1) Tailgate Trim Panel(LH) (3) Tailgate Lock Assembly
Removal
2. Remove the tailgate trim panel (LH).
D Refer to the Tailgate Trim Panel (LH) in
3. Taking notice of the tailgate harness, peel the
waterproof sheet off the tailgate panel carefully and
then remove the waterproof sheet.
684RS005
4. Disconnect the locking links (arrow marks positions),
remove three fixing screws and then remove the
tailgate lock assembly (LH).
683RS003
Legend
(2) To Actuator
Installation
moving surface.
2. Tighten the tailgate lock assembly fixing screws to the
specified torque.
3. Check that the tailgate lock operates correctly after
installing it.
Tailgate Lock Assembly (RH)

Tailgate Lock Assembly (RH) and Associated Parts
684RW006
Legend (4) Clip

(1) Tailgate Trim Panel (RH) (5) Screw
(2) Waterproof Sheet (6) Tailgate Lock Assembly (RH)
(3) Tailgate Lock Seal
Removal
2. Remove the tailgate trim panel (RH).
D Refer to Tailgate Trim Panel (RH) in Exterior/Interior
Trim section.
3. Peel the waterproof sheet off the tailgate panel
carefully and then remove the waterproof sheet.
4. Remove three fixing bolts and then remove the
tailgate lock assembly (RH).
683RW009
5. Remove the tailgate lock seal fixing clip(1) and then
remove the tailgate lock seal(2).
683RW008
Installation
moving surface.
2. Tighten the tailgate lock assembly fixing bolts to the
specified torque.
3. Check that the tailgate lock operates correctly after
installing it.
Tailgate Inside Lock Knob

2. Remove the tailgate trim panel (LH)(2).
D Refer to the Tailgate Trim Panel (LH) in
3. Take care of cushion to turn the lock knob
counterclockwise and then remove the tailgate inside
lock knob(1).
683RW007
Tailgate Outside Handle and/or Tailgate Lock Cylinder

Tailgate Outside Handle and/or Tailgate Lock Cylinder and Associated Parts
684RW003
Legend (4) Tailgate Lock Cylinder

(1) Tailgate Trim Panel (LH) (5) Tailgate Outside Handle
(2) Waterproof Sheet (6) Key Switch
(3) Grommet
Removal
2. Remove the tailgate trim panel.
D Refer to the Tailgate Lock Assembly (LH) in this
section.
4. Remove the grommet.
5. Disconnect the locking links (arrow marks positions), Installation
key switch connector (w/anti-theft) and remove three
fixing bolts to remove the tailgate outside handle. To install, follow the removal steps in the reverse order,
1. For the anti-theft system, install the push rod(1) of the
key switch(3) to the key cylinder(2) while pressing it
so that there is not continuity between the key switch
side connector terminals No. G5–2 and G5–4 as
shown in the figure.
683RS007
Legend
(1) To Actuator
(2) Key Switch Connector
(3) To Lock Assembly
683RS009
6. Remove the key switch fixing bolt(3) to remove the 2. Tighten the outside handle and key cylinder fixing
key switch(4) from the tailgate lock cylinder bolts to the specified torque.
(w/anti-theft)(1). Torque: 9 N·m (78 lb in)
And remove the tailgate lock cylinder fixing bolt(2) to
remove the tailgate lock cylinder. 3. Check that the outside handle and key cylinder
operate correctly after installing them.
683RS008
Key
Key Coding
730RW001
Legend (3) Position

(1) Key(Actual Size) (4) Level
(2) Key Code Tag
One key is used for the ignition, door, and tailgate lock Key Styles
cylinders. The keys are cut on both edges to make them
reversible.
Key identification is obtained from the five character key
code stamped on the key code tag. From this key code,
the key code cutting combination can be determined from
a code list (available to owners of key cutting equipment
from suppliers).
If key codes are not available from records or tags, the
key code can be obtained from the right hand door lock
cylinder (if lock has not been replaced). Lock cylinders
supplied by the factory as service parts are unmarked.
If the original key is available, the key code cutting
combination can be determined by laying the key on the
diagram shown in the figure.
730RY00001
Legend
(1) Blank Key Style “A”
(2) Blank Key Style “B”
The keys come in styles A or B depending on the key code

cutting combination. When the first position in the
combination is a 1, 2 or 3, Style A is used. When the first
position is a 4, Style B (factory pre-cut key) is used.
Power Door Lock System

General Description
The circuit consists of the door lock (& power window)
switch, door lock actuator for the front and rear door,
tailgate lock actuator and the door lock key switch. The
front door lock switch –LH is always provided with battery
voltage.
The key or the inside lock button on the both driver’s and
the front passenger’s door can activate the lock
mechanism of all the doors (including the tailgate).
When the driver’s door lock switch or the front
passenger’s door lock switch is turned on, current flows
for about one second to the door lock actuator of each
door connected in parallel with the front door lock (&
power window) switch –LH to activate the actuator to lock
and unlock the doors.
Front Door Lock Actuator Removal

1. Refer to the Front Door Lock Assembly removal
procedure in this section. 632RS020
2. Remove the door lock actuator(1).

Front Door Lock Actuator Installation
Rear Door Lock Actuator Removal

1. Refer to the Rear Door Lock Assembly removal
procedure in this section.
2. Removal the door lock actuator(1).
632RS021
632RS019
Rear Door Lock Actuator Installation

Tailgate Lock Actuator Removal

1. Refer to the Tailgate Lock Assembly removal
procedure in this section.
2. Remove the tailgate lock actuator(1).
632RY00002
Tailgate Lock Actuator Installation

Anti-theft System
General Description
The circuit consists of the starter switch, anti-theft &
keyless entry control unit, anti-theft horn, front door and
tailgate key switch (detect and tamper switch), door lock
(& power window) switch, door lock actuator for each
door, engine hood switch, clutch start switch (M/T),
ANTI-THEFT indicator light and mode switch (A/T).
The system operates as follows: After locking the starter
switch and removing the starter key (this sets the alarm),
if the door is unlocked in any way other than with the
proper key, the headlights start flashing, the horn sounds,
and the starter circuit is disabled. (However, the engine
hood and all the doors must be locked and closed.)
Once the system has been placed in the warning or alarm
condition, it can be released only when the starter switch
is shifted from “OFF” to “ACC” by the starter key, or when
the lock of the front door or the tailgate is released (to
activate the detect switch) by the starter key.
Anti-theft & Keyless Entry Control 825RW028
Unit Removal Anti-theft & Keyless Entry Control

1. Disconnect the battery ground cable. Unit Installation
2. Remove the front console assembly. To install, follow the removal steps in the reverse order.
D Refer to the Instrument Panel Assembly in Body
Structure section.
3. Remove the lower cluster assembly.
Anti-theft Indicator Removal
D Refer to the Instrument Panel Assembly in Body 1. Disconnect the battery ground cable.
Structure section. 2. Remove the front console assembly(1).
4. Disconnect the connector(2). D Refer to the Instrument Panel Assembly in Body
5. Remove four screws to remove the anti-theft & Structure section.
keyless entry control unit with bracket(1). 3. Remove the lower cluster assembly(2).
Structure section.
assembly(3).
Structure section.
825RW029
6. Remove two nuts from the anti-theft & keyless entry

control unit with bracket(3) to remove the anti-theft &
keyless entry controller(4).
821RW024
5. Remove the instrument panel cluster assembly(4). Anti-Theft Horn Installation
D Refer to the Instrument Panel Assembly in Body To install, follow the removal steps in the reverse order.
Structure section.
6. Remove two screws and then remove the anti-theft
indicator(5). Engine Hood Switch Removal
2. Remove the cap(1).
3. Remove the lock nut(2).
4. Disconnect the connector(4).
5. Remove the engine hood switch(3).
821RW032
Anti-theft Indicator Installation

Anti-theft Horn Removal 828RS011

2. Disconnect the connector and remove the fixing bolt
Engine Hood Switch Installation
to remove the anti-theft horn(1). To install, follow the removal steps in the reverse order.
828RS007
Keyless Entry System

ID Code Registration
There are four kinds of ID codes which can be registered,
for which these two modes, ID code new registration and
ID code additional registration, are available.
ID Code New Registration
This procedure erases all registered ID codes and
registers a new received ID code instead.
Step Action Yes No
1 1. Confirm that all the doors are closed and unlocked.

2. Open the driver’s side door.
3. Insert the key into the starter switch.
Is the action complete? Go to Step 2 Go to Step 1
2 Turn the starter switch to ACC position and then to OFF position
three times.
NOTE: This step must be carried out within five seconds after step
1.
3 Close the driver’s side door and then open it two times.
NOTE: This step must be carried out within ten seconds after step
2.
4 1. Turn the starter switch to ACC position and then to OFF
position five times.
2. Close the driver’s side door and then open it.
3.
5 The control unit locks and unlocks the doors one time.
Does the control unit work normally? Go to Step 6 Go to Step 1
6 Operate the lock or unlock button of the transmitter.
NOTE: This step must be carried out within twenty seconds after
step 5.
Step Action Yes No

step 7.
9 The control unit compares the two codes sent from the
transmitter.
If the code succeeds in registration, the control unit locks and
unlocks the doors one time.
If the two codes are different from each other or fails in
registration, the control unit locks and unlocks the doors three
times.
NOTE: In any case, this procedure is finished.
ID Code Additional Registration

This procedure additionally registers a new received ID
code with holding registered ID codes. When total
number of registered ID codes and newly registered ID
code exceeds four, they are erased in order of older one.
Step Action Yes No

1 1. Confirm that all the doors are closed and unlocked.
2. Open the driver’s side door.
3. Insert the key into the starter switch.
2 Turn the starter switch to ACC position and then to OFF position
three times.
NOTE: This step must be carried out within five seconds after step
1.
3 Close the driver’s side door and then open it two times.
2.
4 1. Turn the starter switch to ACC position and then to OFF
position three times.
2. Close the driver’s side door and then open it.
3.
5 The control unit locks and unlocks the doors two times.
step 5.
Step Action Yes No

step 7.
9 The control unit compares the two codes sent from the
transmitter.
If the code succeeds in registration, the control unit locks and
unlocks the doors one time.
If the two codes are different from each other or fails in
registration, the control unit locks and unlocks the doors three
times.
NOTE: In any case, this procedure is finished.
Anti–theft & Keyless Entry Control

Unit/Transmitter Replacement
Anti–theft & Keyless Entry Control Unit
Replacement
1. Remove and install the control unit.
D Refer to Anti–theft & Keyless Entry Control Unit
Removal and Installation in this section.
2. Register ID code.
D Refer to ID Code Registration in this section.
3. Check that the keyless entry system works normally.
Transmitter Replacement
1. Prepare a new transmitter.
2. Regiter ID code.
D Refer to ID Code Registration in this section.
Transmitter Battery Replacement

1. Remove a screw to remove the cover.
2. Remove the batteries.
3. Set the new batteries into the transmitter.
4. Install the cover to the transmitter.

Front Door Lock Assembly Fixing Screws 7 — 61
Front Outside Handle and Key Switch Fixing Bolts 9 — 78
Rear Door Lock Assembly Fixing Screws 7 — 61
Rear Outside Handle Fixing Bolts 9 — 78
Tailgate Lock Assembly (LH) Fixing Screws 7 — 61
Tailgate Lock Assembly (RH) Fixing Bolts 11 — 95
Tailgate Outside Handle and Key Cylinder Fixing Bolts 9 — 78
SUN ROOF/CONVERTIBLE TOP 8I–1
TROOPER

SUN ROOF/CONVERTIBLE TOP
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 8I–1 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–8
Sun Roof Glass . . . . . . . . . . . . . . . . . . . . . . . . . 8I–2 Sun Roof Drain Hose (Front Side) . . . . . . . . . 8I–9
Sun Roof Glass and Associated Parts . . . . 8I–2 Sun Roof Drain Hose (Front Side)
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–2 and Associated Parts . . . . . . . . . . . . . . . . . . 8I–9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–3 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–9
Sun Roof Deflector . . . . . . . . . . . . . . . . . . . . . . 8I–4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–4 Sun Roof Drain Hose (Rear Side) . . . . . . . . . 8I–10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–4 Sun Roof Drain Hose (Rear Side)
Sunshade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–4 and Associated Parts . . . . . . . . . . . . . . . . . . 8I–10
Disassembled View . . . . . . . . . . . . . . . . . . . . 8I–4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–5 Sun Roof Switch . . . . . . . . . . . . . . . . . . . . . . . . 8I–11
Sun Roof Frame Complete Assembly . . . . . . 8I–6 General Description . . . . . . . . . . . . . . . . . . . . . 8I–11
Sun Roof Frame Complete Assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–11
and Associated Parts . . . . . . . . . . . . . . . . . . 8I–6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–6 Sun Roof Motor . . . . . . . . . . . . . . . . . . . . . . . . . 8I–12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–12
Disassembled View . . . . . . . . . . . . . . . . . . . . 8I–7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–12
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 8I–7 Main Data and Specifications . . . . . . . . . . . . . 8I–13

systems.
8I–2 SUN ROOF/CONVERTIBLE TOP
Sun Roof Glass

Sun Roof Glass and Associated Parts
665RS002
Legend (3) Decoration Cover

(1) Sun Roof Weatherstrip (4) Sun Roof Shim
(2) Sun Roof Glass
Removal
1. Open the sun roof and pull the sun roof weatherstrip
out from the roof panel.
3. Close the sun roof and open the sunshade(1). Then,
remove the decoration cover fixing screws and
decoration cover(2).
665RS003
4. Remove eight sun roof glass fixing screws to remove 3. Temporarily install the glass to the sun roof frame.
the sun roof glass(3). 4. Open and shut the sun roof four to five times to
NOTE: If shims are used between the sun roof set plate position correctly the sun roof weatherstrip and the
and the glass, note the number of shims used. glass in the longitudinal and latitudinal setting
positions.
5. Insert the original shims between the sun roof set
plate and the glass.
6. Tighten the sun roof glass fixing screws to the
specified torque.
7. After the sun roof glass is installed, check the roof
panel and sun roof glass for vertical install position.
If out of standard, adjust with shim.
For the installation standard, refer to Body Dimension
in Body Structure section.
8. Install the decoration cover.
665RS004
Installation
1. Clean the body panel of the weatherstrip fixing
portion.
D If the protective film(1) of the body panel is peeled, it
cannot be reused.
Install the new protective film around the body
panel(2).
2. Install the new weatherstrip(3).
D Always replace with a new one.
D Be sure to install the sun roof weatherstrip so that
the white marking location(4) of the weatherstrip is
on the front side of the vehicle.
665RW016
Sun Roof Deflector

1. Open the sun roof. To install, follow the removal steps in the reverse order.
2. Remove the fixing screws(2) to remove the sun roof
deflector(1).
665RS006
Sunshade
Disassembled View
665RS007
Legend (3) Decoration Cover
(1) Sunshade (4) Sun Roof Deflector
(2) Sunshade Stopper
Removal
1. Remove the decoration cover.
2. Open the sun roof half position, remove the sunshade
stopper screw and pull out the sunshade(6) until its
front side protrudes a little from the sun roof glass(2)
to remove the sunshade stopper.
3. Remove the sun roof deflector.
D Refer to the Sun Roof Deflector in this section.
4. Open the sun roof completely.
5. Remove the sunshade guide rail stopper(5), and pull
out the sunshade up to the rail edge.
6. Remove the guide pin(4) in the sunshade through the
notch(7) of guide rail(1) and then draw the sunshade
out of the roof by pushing inward the retaining clips(3)
on both sides.
665RS008
Installation
Sun Roof Frame Complete Assembly

Sun Roof Frame Complete Assembly and Associated Parts
665RS009
Legend (3) Headlining

(1) Sun Roof Drain Hose (4) Sun Roof Drain Hose
(2) Sun Roof Frame Complete Assembly
Removal
2. Remove the headlining.
D Refer to the Headlining in Body Structure section.
3. Disconnect the sun roof drain hose at the sun roof
frame side as shown in the figure.
665RS010
4. Disconnect the sun roof harness connection.

5. Remove two sun roof frame complete assembly fixing 1. Tighten the sun roof frame complete assembly fixing
nuts (front side) and four fixing bolts (each side) from bolts and nuts to the specified torque.
the frame complete, and then remove the sun roof Torque: 10 N·m(87 lb in)
frame complete assembly.
2. After installing the frame complete, loosen the sun
NOTE: Be sure to remove the frame complete while roof glass fixing nuts and adjust the sun roof glass
supporting it. setting position.
D Refer to the Sun Roof Glass in this section.
Installation
Disassembled View
665RW035
Legend (4) Sun Roof Drive Unit Assembly

(1) Sunshade (5) Outer Tube Fixing Screw
(2) Sun Roof Glass (6) Sun Roof Frame Assembly
(3) Sun Roof Motor (7) Sun Roof Deflector
Disassembly
1. Open the sun roof.
2. Remove the sun roof deflector fixing screws and then
remove the sun roof deflector.
3. Remove the sunshade.
D Refer to the Sunshade in this section.
4. Close the sun roof, remove the decoration cover and
the fixing screws and then remove the sun roof glass.
5. If the shims are used between the sun roof set plate
and the glass, note the number of the shims.
6. Disconnect the sun roof motor connector, remove the
sun roof fixing nuts and screws, and then remove the
sun roof motor.
7. Remove the cable outer tube(2) fixing screws.
8. Remove the cable outer tube fixing clamps(1) and
guide rail fixing nuts(5).
9. Prying the guide rail a little with a screwdriver, draw
the outer tube out of the grommet(3).
D At this time, the inner cable(4) remains on the frame
assembly.
10. Remove the sun roof frame assembly.
665RS013
665RS012
Reassembly
To reassembly, follow the disassembly steps in the
1. When installing the motor or drive unit, set the sun
roof set plate in the full closed position by pushing the
link(3) portion using the screwdriver(2).
2. When installing the sun roof glass(1) to the sun roof
set plate, insert the original shims in the same position
before removing the sun roof glass.
Sun Roof Drain Hose (Front Side)

Sun Roof Drain Hose (Front Side) and Associated Parts
665RS014
Legend (4) Front Inner Liner

(1) Clip (5) Headlining
(2) Sun Roof Drain Hose (6) Instrument Panel Assembly
(3) Grommet
1. Remove the front inner liner. To install, follow the removal steps in the reverse order,
1. Apply the soap and water to the body panel grommet.
2. Install the drain hose from inside of the vehicle by
3. Remove the instrument panel assembly.
utilizing, as a guide, the string passed during removal
D Refer to the Instrument Panel Assembly in Body step.
Structure section.
3. The body panel grommet must not be twisted or
4. Disconnect the drain hose at the frame complete caught in during installation.
side.
4. Complete routing, avoiding extreme bends or curves.
5. After routing, install the trim with care not to allow the
6. Pass the string from the sun roof frame side through drain hose to be caught in.
the drain port side, and remove the drain hose from
6. Test the drain condition.
the hose fixing clips. Taking care not to allow the body
panel grommet to be removed together with the hose, 7. The protrusion of drain hose from the body panel
pull the drain hose only to the inside of the vehicle. must be within 50 mm (2.0 in). If it exceeds 50 mm
(The string should be kept as it is.) (2.0 in) after correct routing, cut the leading edge so
that the protrusion is within 50 mm (2.0 in).
Sun Roof Drain Hose (Rear Side)

Sun Roof Drain Hose (Rear Side) and Associated Parts
665RS015
Legend (6) Tape

(1) Soft Tape (7) Grommet
(2) Pipe (8) Grommet
(3) Clip (9) Clip
(4) Soft Tape (10) Headlining
(5) Sun Roof Drain Hose (11) Rear Fender Inner Liner
Removal 5. Remove the hose fixing tapes and clips.

7. Pull the drain hose to the inside of the vehicle.
2. Remove the rear fender inner liner.
D Refer to the Headlining in Body Structure section. Installation
4. Disconnect the drive hose at the frame complete side. To install, follow the removal steps in the reverse order,
1. Apply the soap and water to the body panel grommet. 4. Test the drain condition.
2. Insert the drain hose from inside of vehicle, restore 5. The protrusion of the drain hose from the body panel
routing, and fix with new soft tape and clip. must be within 50 mm (2.0 in). If it exceeds 50 mm
If the grommet is removed during removal of drain (2.0 in) after correct routing, cut the leading edge so
hose, insert the grommet into drain hose from outside that the protrusion is within 50 mm (2.0 in).
of the vehicle, and install on the body panel, avoiding
any twisting.
3. After installing the drain hose, install the trim while
taking care not to crush the drain hose.
Also, care should be taken not to allow the drain hose
connected to the pipe to be caught in.
Sun Roof Switch

General Description
Sun roof operation can be controlled by pushing
continuously the sun roof switch to activate the sun roof
control unit and sun roof motor.
While the switch is being pushed to the “OPEN” side, the
sun roof stops about 165 mm (6.5 in) before fully open
position. Push the switch again to the “OPEN” side to
open it fully. When the switch is being continuously
pushed to the “CLOSE” side, the sun roof stops about
180 mm (7.1 in) short of the fully closed position and
remains in this state. Push the switch again to the
“CLOSE” side to close it completely.
Removal
2. Pull down the switch housing(2) and disconnect the
sun roof switch and map light connectors to remove
the sun roof switch(1). 805RS002
Installation
Sun Roof Motor

Removal
2. Remove the headlining(2).
3. Disconnect the connector, and remove three nuts and
two screws to remove the sun roof motor(1).
665RW034
Installation

Sun Roof Frame Complete Assembly Fixing Bolts 10 — 87
Sun Roof Glass Fixing Screws 10 — 87
EXTERIOR/INTERIOR TRIM 8J–1
TROOPER

EXTERIOR / INTERIOR TRIM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 8J–2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–20
Dash Side Trim Panel . . . . . . . . . . . . . . . . . . . . 8J–3 Center Pillar Assist Grip . . . . . . . . . . . . . . . . . . 8J–20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–3 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8J–20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–3 Removal and Installation . . . . . . . . . . . . . . . 8J–20
Assist Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–3 Assist Grip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–21
Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8J–3 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8J–21
Removal and Installation . . . . . . . . . . . . . . . 8J–3 Removal and Installation . . . . . . . . . . . . . . . 8J–21
Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–4 Fuel Filler Lid Opener Cable . . . . . . . . . . . . . . 8J–22
Consoles and Associated Parts . . . . . . . . . 8J–4 Fuel Filler Lid Opener Cable and
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–4 Associated Parts . . . . . . . . . . . . . . . . . . . . . . 8J–22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–22
Front Door Trim Panel . . . . . . . . . . . . . . . . . . . 8J–6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–23
Front Door Trim Panel and Associated Fuel Filler Door . . . . . . . . . . . . . . . . . . . . . . . . . 8J–23
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–6 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8J–23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–23
Rear Door Trim Panel . . . . . . . . . . . . . . . . . . . . 8J–10 Rocker Protector (Without Wheel Opening
Rear Door Trim Panel and Associated Extension) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–24
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–10 Rocker Protector (Without Wheel Opening
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–10 Extension) and Associated Parts . . . . . . . . 8J–24
Door Wood Panel Assembly . . . . . . . . . . . . . . 8J–13 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–24
Door Wood Panel Assembly and Wheel Opening Extension and Rocker
Associated Parts . . . . . . . . . . . . . . . . . . . . . . 8J–13 Protector Assembly . . . . . . . . . . . . . . . . . . . . . 8J–25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–13 Wheel Opening Extension, Rocker Protector
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–13 Assembly and Associated Parts . . . . . . . . . 8J–25
Door Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–14 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–25
Door Mirror and Associated Parts . . . . . . . . 8J–14 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–14 Mud Flaps (With Wheel Opening Extension) 8J–27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–14 Mud Flaps (With Wheel Opening Extension)
and Associated Parts . . . . . . . . . . . . . . . . . . 8J–27
Luggage Side and Quarter Upper Trim
Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–27
Luggage Side, Quarter Upper Trim Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–27
and Associated Parts . . . . . . . . . . . . . . . . . . 8J–15 Ventilation Assembly . . . . . . . . . . . . . . . . . . . . . 8J–28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–15 Ventilation Assembly and Associated Parts 8J–28
Center Pillar and Roof Side Trim Cover . . . . 8J–17 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–28
Center Pillar, Roof Side Trim Cover and Tailgate Trim Panel (LH) . . . . . . . . . . . . . . . . . 8J–29
Associated Parts . . . . . . . . . . . . . . . . . . . . . . 8J–17 Tailgate Trim Panel (LH) and Associated
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–18 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–29
Front Pillar Trim Cover . . . . . . . . . . . . . . . . . . . 8J–19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–29
Front Pillar Trim Cover and Associated Tailgate Trim Panel (RH) . . . . . . . . . . . . . . . . . 8J–30
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–19 Parts Location . . . . . . . . . . . . . . . . . . . . . . . . 8J–30
8J–2 EXTERIOR/INTERIOR TRIM
Luggage Floor Box . . . . . . . . . . . . . . . . . . . . . . 8J–31 Power Door Mirror . . . . . . . . . . . . . . . . . . . . . . . 8J–32
Luggage Floor Box and Associated Parts . 8J–31 General Description . . . . . . . . . . . . . . . . . . . . 8J–32
Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–31 Removal and Installation . . . . . . . . . . . . . . . 8J–32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–31 Power Window System . . . . . . . . . . . . . . . . . . 8J–33
Rope Hook Set . . . . . . . . . . . . . . . . . . . . . . . . . 8J–31 General Description . . . . . . . . . . . . . . . . . . . . . 8J–33
Rope Hook Set and Associated Parts . . . . 8J–31 Power Window Switch Removal and
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–31 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–31 Power Window Motor Removal and
Power Door Mirror System . . . . . . . . . . . . . . . 8J–32 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J–34
General Description . . . . . . . . . . . . . . . . . . . . . 8J–32 Main Data and Specifications . . . . . . . . . . . . . 8J–35
Door Mirror Switch Assembly (Control
Switch, Folding Switch and Defogger
Switch) Removal . . . . . . . . . . . . . . . . . . . . . . 8J–32

systems.
Dash Side Trim Panel

2. Remove the front door sill plate(2).
1. Lap the door inner seal over the trim panel to install
3. Remove the dash side trim panel(3).
them securely to the body panel.
D Turn up the door inner seal(1) of the body panel to
remove the clips of the trim panel.
D Take care not to damage the harness and the
controller on the back of the trim panel.
643RS007
Assist Grip
Parts Location
745RS002

D Refer to the Consoles removal and installation steps
in this section.
Consoles
Consoles and Associated Parts
745RX001
Legend (4) Center Console Assembly

(1) Shift Knob (M/T) / Transfer Knob (A/T) (5) Fuel Filler Lid Opener
(2) Front Console Assembly (6) Assist Grip
(3) Front Seat Assembly (RH)
Removal
2. Remove the shift knob (M/T) / transfer knob (4x4
only).
3. Remove the front console assembly.
D Remove four fixing screws and disconnect the
switch connectors.
4. Remove the front seat assembly(RH).
D Refer to Front Seat Assembly in Seats section.
5. Remove the assist grip.
D Remove three bolts.
6. Remove the fuel filler lid opener.
D Remove the fuel filter lid opener(1) and disconnect
the cable(2).
686RS001
7. Remove the center console assembly(2).
D Remove two fixing screws on the front side.
Open the rear cover, remove two nuts, then the
center console assembly.
D Remove the rear heater duct(1) from the center
console.
745RS005
Installation
Front Door Trim Panel

Front Door Trim Panel and Associated Parts
635RS006
Legend (8) Regulator Handle

(1) Power Window Switch (9) Inside Handle Fixing Screw
(2) Door Mirror Cover/Tweeter (10) Inside Handle
(3) Door Wood Panel (11) Hook
(4) Door Trim Panel (12) Washer
(5) Courtesy Light (13) Inside Pull Handle
(6) Front Speaker (14) Inside Pull Handle (W/O Power Window)
(7) Speaker Cover
Removal
2. Remove the door mirror cover/tweeter(1). 4. Remove the power window switch(5).
D On a model equipped with a tweeter, remove the D Pry the power window switch out and disconnect
connector(2). the switch connector.
720RS007 825RW045
3. Remove the regulator handle(3). 5. Remove the speaker cover.

D Pull the hook(4) out and remove the regulator 6. Remove the front speaker.
handle. D Remove the front speaker fixing screws in order to
disconnect the speaker connector.
7. Remove the inside handle fixing screw.
D Remove the screw that fixes the inside handle(7),
slide the inside handle to the position illustrated,
and leave it there for the moment.
CAUTION: Take care not to impose excessive force
on the inside handle link(6), lest this link is
elongated, which could make it impossible to
operate the door with the inside handle.
631RW001
D Disconnect the courtesy light connector(13) to lift
the door trim panel(14) and unlock the engagement
of the waist seal(12) section. Then, pass the inside
handle(11) through the mounting hole of the trim
panel, and detach the trim panel.
632RW001

D Remove two fixing screws(8) in order to take off
seven clips(10) from the door panel.
632RS015
9. Remove the inside handle.

10. Remove the door wood panel.
D Refer to the Door Wood Panel Assembly in this
section.
635RS007
Installation
1. When installing the inside handle(2), assemble it
temporarily to the inside handle link(1).
632RW006
3. Fit the claw(10) of the inside handle(11) securely into

the hole of the door panel and fix the inside handle
with the screw.
632RS014
2. Pass the inside handle(4) through the mounting hole

of the trim panel and assemble the trim panel.
Engage seven clips(8) into the door panel. Also,
connect the courtesy light connector(5) and leave the
connectors of the speaker(7), tweeter(9) and power
window(3) drawn out to their prescribed positions, so
that they will not be caught.
Then, put the inside handle(4) to the normal position
of the inside handle link(6).
632RW007
Rear Door Trim Panel

Rear Door Trim Panel and Associated Parts
655RS003
Legend (5) Washer

(1) Power Window Switch (6) Clip
(2) Door Wood Panel (7) Regulator Handle
(3) Courtesy Light (8) Inside Handle Fixing Screw
(4) Door Trim Panel (9) Inside Handle
Removal
2. Remove the regulator handle(1).
D Pull the hook(2) out and remove the regulator
handle.
631RW002
3. Remove the power window switch(3). 5. Remove the door trim panel(6).
D Pry the power window switch out and disconnect D Remove two fixing screws(8) to take off seven
the switch connector. clips(7) from the door panel.
825RS084 655RS004
4. Remove the inside handle fixing screw. D Unplug the courtesy light connector to lift the trim
D Remove the screw that fixes the inside handle(5), panel and unlock the engagement of the waist seal
slide the inside handle to the position illustrated, section. Then, pass the inside lever through the
and leave it there for the moment. mounting hole of the trim panel, and detach the trim
panel.
CAUTION: Take care not to impose excessive force
on the inside handle link(4), lest this link be 6. Remove the inside handle.
elongated, which could make it impossible to 7. Remove the door wood panel.
operate the door with the inside handle. D Refer to the Door Wood Panel Assembly in this
section.
Installation
1. When installing the inside handle(1), assemble
temporarily to the inside handle link(2).
652RS006
632RW002
2. Pass the inside handle through the mounting hole of
the trim panel. Assemble the trim panel. Engage
securely seven clips into the door panel. Also,
connect the courtesy light connector. Leave the
connector of the power window drawn out to its
prescribed position, so that it will not caught.
3. Put back the inside handle(3) to the original position
of the link(5). Fit the claw(4) of the inside handle
securely into the hole of the door panel. Fix the
handle with the screw.
632RW011
Door Wood Panel Assembly

Door Wood Panel Assembly and Associated Parts
635RS010
Legend
(1) Door Trim Panel
(2) Door Wood Panel Assembly
Removal
D Refer to the Front / Rear Door Trim Panel in this
section.
2. Remove the door wood panel assembly(2).
D Remove four door wood panel assembly fixing
screws and washers.
NOTE: The removal and installation steps are common
to both front and rear doors.
635RS009
Installation
Door Mirror
Door Mirror and Associated Parts Installation
1. When you install the door mirror, install the bolt(1) to
the mirror temporarily, hook the bolt to the door side
hole and tighten the bolt from the inside.
720RS012
Legend
(1) Door Mirror Cover / Tweeter
(2) Door Mirror Connector
(3) Door Mirror
720RS001
2. When installing the door mirror, hold the glass run

lip(2) between the door mirror base(3) and the center
Removal sash(4).
2. Remove the door mirror cover(1).
D Remove the connectors(2) and the door mirror
cover, if equipped with a tweeter.
A10RS001
3. Tighten the door mirror fixing bolts to the specified

torque.
720RS007
3. Remove the door mirror connector.

4. Remove the door mirror.
Luggage Side and Quarter Upper Trim Cover

Luggage Side, Quarter Upper Trim Cover and Associated Parts
687RS001
Legend (6) Rear End Floor Trim Cover

(1) Quarter Upper Trim Cover (7) Luggage Side Cap
(2) Rear Seat Belt Anchor Bolt Cover and Anchor (8) Speaker Grille
Bolt (9) Rear Speaker
(3) Roof Side Trim Cover (10) Clip
(4) Luggage Side Lower Cover (11) Luggage Room Light
(5) Luggage Side Trim Cover (12) Rear Roof Trim Cover
Removal
2. Remove the rear end floor trim cover.
3. Remove the luggage side cap.
4. Remove the luggage side lower cover.
5. Remove the luggage side trim cover (1).
D Remove the rear side fixing screws and pry the trim
cover retainers free from the body panel and the
upper trim cover.
687RS002 687RS003
6. Remove the luggage room light. 9. Remove the rear speaker.

D Remove the luggage room light lens and the fixing D Remove the rear speaker fixing screws and
screws. disconnect the connector.
D Disconnect the luggage room light connector. 10. Remove the rear seat belt anchor bolt cover (2) and
the anchor bolt (3).
7. Remove the rear roof trim cover.
D Pry the trim cover retainers free from the body
panel.
760RW005
11. Remove the quarter upper trim cover.

D Remove the rear side clips of the trim cover and pry
666RS001
the quarter upper trim cover retainers free from the
8. Remove the speaker grille.
body panel.
Installation
1. Tighten the seat belt anchor bolt to the specified
torque.
687RS004
Center Pillar and Roof Side Trim Cover

Center Pillar, Roof Side Trim Cover and Associated Parts
643RW003
Legend (6) Door Sill Plate (Front and Rear)

(1) Roof Side Trim Cover (7) Center Pillar Lower Trim Cover
(2) Front Pillar Trim Cover (8) Front Seat Anchor Bolt Cover and Anchor Bolt
(3) Assist Grip (RH only) (9) Center Pillar Assist Grip
(4) Adjust Shoulder Anchor Assembly (10) Assist Grip
(5) Center Pillar Upper Trim Plate (11) Rear Quarter Upper Trim Cover
Removal 5. Remove the center pillar upper trim cover (6).

D Turn up the finisher (5) and pry the trim cover
1. Disconnect the battery ground cable. retainers free from the body panel.
2. Remove the door sill plate (front and rear).
3. Remove the center pillar lower trim cover (2).
D Turn up the finisher (1) and pry the trim cover
retainers free from the body panel, then slide the
trim cover downward.
643RS004
6. Remove the center pillar assist grip.

7. Remove the seat belt anchor plate.
8. Remove the assist grip (7).
D Open the both side of the assist grip cover (8) and
643RS003
remove two fixing screws.
4. Remove the front seat belt anchor bolt cover (3) and
the anchor bolt (4).
743RW004
760RW006
9. Remove the roof side trim cover (9). Installation
D Turn up the finisher (10) and pry the trim cover To install, follow the removal steps in the reverse order,
retainers free from the body panel. noting the following point.
1. Install the seat belt anchor bolts to the specified
torque.
643RS005
Front Pillar Trim Cover

Front Pillar Trim Cover and Removal
Associated Parts 1. Remove the front pillar assist grip(1).
D Open the both sides of the assist grip cover (2) and
remove the fixing screws and the front pillar assist
grip.
743RS003
Legend
(1) Roof Side Trim Panel
(2) Assist Grip (RH only) 743RW003
(3) Front Pillar Trim Panel

2. Remove the front pillar trim cover (3). Installation
D Turn up the finisher (4) and pry the trim cover To install, follow the removal steps in the reverse order.
retainers free from the body panel.
635RW001
Center Pillar Assist Grip

Parts Location Removal and Installation
Refer to the Center Pillar and Roof Side Trim Cover in this
section.
743RS004
Legend
(1) Center Pillar Assist Grip
Assist Grip
Parts Location
743RS005
Legend
(1) Assist Grip

Refer to the Center Pillar and Roof Side Trim Cover in this
section.
Fuel Filler Lid Opener Cable

Fuel Filler Lid Opener Cable and Associated Parts
686RW002
Legend (7) Center Console Assembly

(1) Rear End Floor Trim Cover (8) Fuel Filler Lid Opener
(2) Fuel Filler Lid Opener Cable (9) Front Seat (RH)
(3) Chassis Harness (10) Center Pillar Lower Trim Cover
(4) Cable (11) Rear Door Sill Plate (RH)
(5) Marking (12) Luggage Side Trim Panel (RH)
(6) Clip
Removal
2. Remove the front seat (RH).
3. Remove the rear door sill plate (RH).
4. Remove the center pillar lower trim cover.
5. Remove the rear end floor trim panel.
6. Remove the luggage side trim panel (RH).
D Refer to the Luggage Side and Quarter Upper Trim
Cover in this section.
7. Remove the fuel filler lid opener(1). Installation
D Remove two opener fixing screws and disconnect To install, follow the removal steps in the reverse order,
the cable(2). noting the following points.
1. Insert the opener cable(2) into the body panel(1)
securely.
686RS001
8. Remove the center console assembly.

9. Remove the filler lid opener cable. 686RS002
D Roll up the floor carpet and remove the clips of the 2. Install the cable and clips to its original position to the
chassis harness and body panel to pull out the chassis harness and the body panel.
cable toward the fuel filter lid. 3. Check that the opener operates smoothly.
Fuel Filler Door

Parts Location Installation
1. Install the fuel filler door.
686RS003
Legend
(1) Fuel Filler Door
Removal
1. Remove the fuel filler door.
Rocker Protector (Without Wheel Opening Extension)

Rocker Protector (Without Wheel Opening Extension) and Associated Parts
603RW002
Legend (7) Outer Wheel House Panel

(1) Rear Rocker Protector (8) Fixing Clip
(2) Inner Liner (9) Outer Rocker Panel
(3) Spare Nut (10) Door Panel
(4) Fixing Screw (11) Front Rocker Protector
(5) Rocker Protector (12) Clip (W/Rocker Protector)
(6) Outer Side Panel (13) Fender Panel
1. Remove the rear rocker protector. To install, follow the remove steps in the reverse order.
2. Remove the front rocker protector.
Wheel Opening Extension and Rocker Protector Assembly

Wheel Opening Extension, Rocker Protector Assembly and Associated Parts
620RW002
Legend (4) Rear Quarter Wheel Opening Extension

(1) Front Wheel Opening Extension Assembly Assembly
(2) Front Rocker Protector Assembly (5) Rear Door Wheel Opening Extension
(3) Rear Rocker Protector Assembly Assembly
Removal
1. Remove the front rocker protector assembly.
D Loosen and pull clips, and remove the front rocker
protector assembly.
2. Remove the rear rocker protector assembly.
D Loosen and pull three clips, remove a rear screw,
and remove the rear rocker protector assembly.
3. Remove the front wheel opening extension(2).
D Let a 5mm drill(3) go through four blind rivets(5) to
disengaged riveted portions.
Remove two screws and disengage five clips, then
remove the front wheel opening extension
assembly.
620RS005
4. Remove the rear quarter wheel opening extension Installation
assembly.
D Let a 5mm drill go through six blind rivets to noting the following points.
disengage riveted portions.
1. Use a new 2–sided adhesive tape whenever installing
Disengage four clips, remove two screws, and
each wheel opening extension assembly and rocker
remove the rear quarter wheel opening extension
protector assembly. Using a white gasoline, clean the
assembly.
places in advance where a 2–sided adhesive tape is
5. Remove the rear door wheel opening extension affixed. Also, install the clips, screws and blind rivets
assembly. in the order specified as shown in the figure.
D Let a 5mm drill go through a blind rivet to disengage
riveted portions.
Disengage three clips, peel off the bonded portions
with two double surface adhesive tape and the rear
door wheel opening extension assembly.
620RW001
Mud Flaps (With Wheel Opening Extension)

Mud Flaps (With Wheel Opening Extension) and Associated Parts
620RW003
Legend (3) Front Mud Flap

(1) Front Bumper Assembly (4) Bumper Side Cover
(2) Front Bumper Slider (5) Rear Mud Flap
Removal 3. Remove the front mud flap.

D Remove four nuts and a clip.
Front Side
1. Remove the front bumper assembly.
D Disconnect the front fog light connector and remove
two bolts from both sides of the front bumper.
2. Remove the front bumper slider(1).
D Remove two clips(4) and two nuts(3), release the
claw from the washer(2).
601RW013
Rear Side
1. Remove the bumper side cover.
2. Remove the rear mud flap.
D Remove four bolts and two nuts.
601RW009
Installation
Ventilation Assembly
Ventilation Assembly and Associated Parts
641RS001
Legend
(1) Outlet Valve Assembly
(2) Ventilation Assembly
1. Remove the ventilation assembly(1). 1. Install the outlet valve assembly.
D Pry the ventilation assembly retainers free from the D Insert the upper and lower catches of the outlet
body panel. valve into the body panel flange and fix them
securely.
2. Install the ventilation assembly.
D Fix the clips to the body panel securely so that the
ventilation assembly will not come off the body
panel.
641RS002
2. Remove the outlet valve assembly.

Tailgate Trim Panel (LH)

Tailgate Trim Panel (LH) and Associated Parts
683RS002
Legend (3) Tailgate Panel

(1) Tailgate Trim Panel (LH) (4) Cap and Screw
(2) Clip
Removal
2. Remove the cap and screw.
3. Remove the tailgate trim panel (LH).
D Pry the trim panel retainers free from the tailgate
panel.
684RS001
Installation
Tailgate Trim Panel (RH)

Parts Location Installation
1. Install the trim panel (RH).
D Insert the retainer of the trim panel into the tailgate
panel and fix it securely.
684RS002
Legend
(1) Tailgate Trim Panel
Removal
2. Remove the tailgate trim panel (RH).
D Pry trim panel retainer free from the tailgate panel.
684RS003
Luggage Floor Box

Luggage Floor Box and Associated Remove
Parts 1. Fold the rear seat assembly to the front direction.
2. Remove the luggage floor box cover.
D Remove the clips which connect the floor carpet
and the luggage floor box cover.
3. Remove the luggage floor box.
Installation
643RS006
Legend
(1) Rear Seat
(2) Floor Carpet
(3) Luggage Floor Box
(4) Luggage Floor Box Cover
Rope Hook Set

Rope Hook Set and Associated Parts Legend
(1) Rope Hook Set
(2) Cover
(3) Luggage Floor Carpet
(4) Hook
Removal
1. Remove the rope hook set.
D Open the hook cover and hook fixing bolt.
Installation
1. Install the rope hook set.
D Tighten the hook fixing bolt to the specified torque.
676RS003
Power Door Mirror System

General Description D Disconnect the power & winter switch connectors.
(A/T only)
The circuit consists of the starter switch, door mirror
control switch, folding switch, defogger switch and door 3. Remove the door mirror switch assembly(1).
mirrors on both sides. D Push the lock from the back side of the front
The door mirror switch consists of the control switch, console.
folding switch and defogger switch.
When the control switch is operated with the starter
switch at either “ACC” or “ON” position, the motors
incorporated in the door mirrors on both sides rotates to
allow the horizontal and vertical adjustment of mirror
angles.
The folding switch can be used to fold the mirror and
return it to its original position.
When turning on the door mirror defogger switch with the
starter switch at “ON” position, built-in heater in the mirror
is activated to perform the defogger function.
Door Mirror Switch Assembly (Con-

trol Switch, Folding Switch and De-
fogger Switch) Removal
D Remove four screws.
825RS005
D Remove the transmission shift lever knob.

D Remove the transfer shift lever knob. Installation
D Disconnect the seat heater switch connectors (if so To install, follow the removal steps in the reverse order,
equipped). noting the following point.
D Disconnect the door mirror switch connectors. 1. Depress the switch with your fingers until it locks
securely.
Power Door Mirror

General Description
Mirrors contain two driving motors for the horizontal and
vertical movement of the mirror and one motor for folding
the mirror.
The movement of the mirror is controlled by the direction
of current running through these motors.
The housing portion of the mirror is provided with the
auto-stop mechanism which is interlocked with the motor
for folding the mirror. When the mirror moves to the stop
position (with the mirror folded or returned to its original
position), the current to the motor is shut off.
When the mirror cannot operate due to some obstacle
and the motor stops its rotation, the resistor prevents
current overflow.
720RS004

Refer to the Door Mirror removal and installation steps in
this section.
Power Window System

General Description 2. Remove the switch(1).
The circuit consists of the starter switch, (door lock &) D Pull out the switch by pushing the spring with the tip
power window switch for each of the front windows, of a screwdriver.
power window switch for rear windows and power window D Disconnect the connector.
motors.
When the starter switch is turned on, the battery voltage is
applied to each of the power window switches through the
circuit breaker and the power window relay on the circuit.
The “Down” switch of the driver’s power window switch
has a built-in function which can be operated by just
touching it.
Accordingly, the window will roll down automatically by
just setting the switch to the “AUTO” position.
When the driver’s power lock switch at the driver side is
depressed, the power source to the passenger’s power
window switches are shut off. So, even if these switches
are operated, the power window motor will not operate.
Power Window Switch Removal and

Installation
Driver Seat Side
Removal
825RW046
Installation
2. Remove the switch(1).
D Pull out the switch by pushing the spring with the tip
of a screwdriver. Rear-Left and Right Sides
D Disconnect two connectors. Removal
2. Remove the switch(1).
D Pull out the switch by pushing the spring with the tip
of a screwdriver.
D Disconnect the connector.
825RS052
Installation
Front Passenger Seat Side

Removal 825RS057

Installation
Power Window Motor Removal and

Installation
Driver Seat Side
Removal
2. Remove the window regulator assembly (1).
D Refer to Front Window Regulator, Glass and Glass
Run in Body Structure section.
3. Remove the power window motor(2).
D Remove three screws.
CAUTION: When removing the motor from the
regulator(1), be careful not to get injured by the
strong repellent force of the regulator spring. 631RS015
Installation
Rear-Left Side
Removal
2. Remove the rear window regulator assembly.
D Refer to Rear Window Regulator and Glass in Body
Structure section.
D Remove four screws.
631RS018
Installation
Front Passenger Seat Side

Removal
2. Remove the window regulator assembly (1).
D Refer to Front Window Regulator, Glass and Glass
Run in Body Structure section.
D Remove three screws. 651RW014
CAUTION: When removing the motor from the Installation

regulator(1), be careful not to get injured by the To install, follow the removal steps in the reverse order.
strong repellent force of the regulator spring.
Rear-Right Side
Refer to the Rear Power Window Motor-Left Side in this
section.

Door Mirror Fixing Bolts 8 — 69
Seat Belt Anchor Bolts 39 29 —
Hook Fixing Bolt 13 — 113
SEAT BELT SYSTEM 9A–1
TROOPER
RESTRAINTS
CONTENTS
Seat Belt System . . . . . . . . . . . . . . . . . . . . . . . . 9A–1
Supplemental Restraint System (SRS) . . . . . 9J–1
Restraint Control System . . . . . . . . . . . . . . . . . 9J1–1
SEAT BELT SYSTEM

CONTENTS
Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–2 Rear Seat Lock Assembly . . . . . . . . . . . . . . . . 9A–6
Front Seat Belt and Associated Parts . . . . 9A–2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–2 Rear Seat Lock Assembly (Bench Type) . . . 9A–6
Rear Seat Belt and Associated Parts . . . . . 9A–3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–4 Rear Seat Strikers . . . . . . . . . . . . . . . . . . . . . . . 9A–7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–7
Front Seat Buckle Assembly . . . . . . . . . . . . . . 9A–4 Child Seat Tether Anchor Bracket
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–4 (Child Restraint) . . . . . . . . . . . . . . . . . . . . . . . . 9A–7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–4 General Description . . . . . . . . . . . . . . . . . . . . . 9A–7
Rear Center Seat Belt / Buckle Assembly . . . 9A–5 Child Seat Tether Anchor Bracket and
Rear Center Seat Belt / Buckle Associated Parts . . . . . . . . . . . . . . . . . . . . . . 9A–7
Assembly and Associated Parts . . . . . . . . . 9A–5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A–5 Main Data and Specifications . . . . . . . . . . . . . 9A–8

systems.
9A–2 SEAT BELT SYSTEM
Seat Belt
Front Seat Belt and Associated Parts
760RW014
Legend (6) Anchor Bolt (Lower)

(1) Center Pillar Upper Trim Cover (7) Door Sill Plate (Front & Rear)
(2) Adjustable Shoulder Anchor Assembly (8) Center Pillar Lower Trim Cover
(3) Center Pillar (9) Front Seat Belt Assembly
(4) Dust Cover (10) Front Seat Belt Anchor Bolt Cover and Anchor
(5) Retractor Bolt
Removal D No smooth move of upper/lower anchors in the

circumferential direction.
1. Disconnect the battery ground cable. D Damaged and/or deformed through ring.
2. Remove the door sill plate (Front & Rear). D Damaged and/or deformed tongue.
3. Remove the center pillar lower trim cover. D Damaged and/or frayed of webbing.
4. Remove the front seat belt anchor bolt cover and D Deformed retractor bracket.
anchor bolt (Upper Side).
D Seat belt not rewound up.
D Refer to Center Pillar and Roof Side Trim Cover in
Exterior/Interior Trim section. D Resistance or abnormal sound when seat belt is
wound out and rewound.
5. Remove the seat belt lower anchor bolt and screw,
and then remove the front seat belt. D Retractor abnormality.
Inspection
If any of the following abnormalities is found, replace on
an assembly basis:
D Deform and malfunction of adjustable shoulder
anchor.
Inspection of retractor CAUTION: Do not disassemble the retractor.

1. ELR (Emergency Locking Retractor) lock inclining
angle check. Installation
D When the retractor is moved gently from its To install, follow the removal steps in the reverse order,
installing position, make sure it is not locked within noting the following points;
15° in any directions, and it remains locked at 45° or
CAUTION: The front seat belt for ’99model is
larger.
differently specified from that for ’98model.
2. ELR lock check. When replacing, be sure to replace with the one for
D When the seat belt is drawn slowly with the retractor ’99model after making sure of part No..
installed, make sure it is not locked. And when it is
1. Pass the seat belt through the lower trim cover hole,
drawn quickly, make sure it is locked.
and tighten the seat belt anchor bolts to the specified
3. ALR (Automatic Locking Retractor)/ELR check torque.
(Except for driver’s seat).
D When rewound after winding out the seat belt,
make sure the seat belt cannot be taken out. After 2. After installing the trim cover to the body panel
rewinding, make sure it has returned to its normal securely, close the lower trim cover.
operation.
Rear Seat Belt and Associated Parts
760RS006
Legend (4) Dust Cover

(1) Rear Seat Belt Anchor Bolt Cover and Anchor (5) Retractor
Bolt (Upper Side) (6) Anchor Bolt (Lower Side)
(2) Quarter Upper Trim Cover (7) Luggage Side Trim Cover
(3) Rear Seat Belt Assembly (8) Rear End Floor Trim Cover
Removal Inspection of retractor

1. Disconnect the battery ground cable. 1. ELR (Emergency Locking Retractor) lock inclining
2. Remove the rear end floor trim cover. angle check.
3. Remove the luggage side trim cover. D When the retractor is moved gently from its
installing position, make sure it is not locked within
D Refer to Luggage Side and Quarter Upper Trim 15° in any directions, and it remains locked at 45° or
Cover in Exterior/Interior Trim section. larger.
4. Remove the rear seat belt anchor bolt cover and 2. ELR lock check.
anchor bolt (Upper Side).
D When the seat belt is drawn slowly with the retractor
5. Remove the seat belt lower anchor bolt and remove installed, make sure it is not locked. And when it is
the retractor from dust cover slit to remove the rear drawn quickly, make sure it is locked.
seat belt.
3. ALR (Automatic Locking Retractor)/ELR check
(Except for driver’s seat).
Inspection D When rewound after winding out the seat belt,
If any of the following abnormalities is found, replace on make sure the seat belt cannot be taken out. After
an assembly basis: rewinding, make sure it has returned to its normal
D No smooth move of upper/lower anchors in the operation.
circumferential direction. CAUTION: Do not disassemble the retractor.
D Damaged and/or deformed through ring.
D Damaged and/or deformed tongue. Installation
D Damaged and/or frayed of webbing. To install, follow the removal steps in the reverse order,
D Deformed retractor bracket. noting the following point.
D Seat belt not rewound up. 1. Tighten the seat belt anchor bolts to the specified
D Resistance or abnormal sound when seat belt is torque.
wound out and rewound. Torque: 39 N·m (29 lb ft)
D Retractor abnormality.
Front Seat Buckle Assembly

2. Disconnect the seat belt warning connector (driver’s
side) (3) and remove a clip(2). 1. Fix the buckle to the rotation-stop position(2) securely
to install the front seat buckle assembly(1).
3. Remove the front seat buckle assembly(1).
760RS005
760RT003
2. Tighten the buckle anchor bolt to the specified torque.
Rear Center Seat Belt / Buckle Assembly

Rear Center Seat Belt / Buckle Assembly and Associated Parts
760RW007
Legend
(1) Rear Seat Belt Buckle Assembly
(2) Seat Lock Cover
1. Remove the catch portions(2) & (3) of the seat lock 1. Fix the rear seat buckle assembly(1) to the rotation
assembly(4) from the cover, and then remove the stopper and tighten the anchor bolt to the specified
seat lock cover(1). torque.
760RW016
2. Remove the rear seat buckle assembly.

760RS013
2. Install the seat lock cover.

Rear Seat Lock Assembly

1. Remove the seat lock cover(3). To install, follow the removal steps in the reverse order,
2. Remove the rear seat belt buckle assembly(1).
1. Tighten the seat lock fixing bolts to the specified
3. Remove the rear seat lock assembly(2).
torque.
Torque:42 N·m (31 lb ft )
760RW002
Rear Seat Lock Assembly (Bench Type)

1. Remove the seat lock cover(3). To install, follow the removal steps in the reverse order,
2. Remove the rear seat belt/buckle assembly(1).
1. Tighten the seat lock fixing bolts to the specified
3. Disconnect the link connecting the lock assemblies
torque.
on the both sides, and then remove the rear seat lock
assembly(2). Torque: 42 N·m (31 lb ft)
760RW003
Rear Seat Strikers

1. Fold the rear seat assembly to the front direction. To install, follow the removal steps in the reverse order,
2. Remove the luggage floor box(1).
1. Tighten the striker fixing bolts to the specified torque.
3. Remove the rear seat striker(2).
755RW015
Child Seat Tether Anchor Bracket (Child Restraint)

General Description Legend
(1) Rear Seat
Plastic plug is provided at three places on the luggage
(2) Luggage Floor
floor panel. Remove the center plug from the floor panel.
Install the bracket to the hole where the plug is removed. (3) Plug
Alternatively, the bracket may be installed in the (4) Child Seat Tether Anchor Bracket
right-hand or left-hand plug hole. (5) Floor Carpet
(6) Child Seat Tether Anchor Bracket
Child Seat Tether Anchor Bracket
and Associated Parts
Installation
1. Turn the plug counterclockwise to remove it.
2. Install the bracket such that its tether belt hook hole is
facing toward the front of the vehicle.
3. Tighten the fixing bolt to the specified torque.
760RW004

Front Seat Belt Anchor Bolts 39 29 —
Rear Seat Belt Anchor Bolts 39 29 —
Front Seat Buckle Anchor Bolt 39 29 —
Rear Seat Buckle Anchor Bolt 39 29 —
Rear Seat Lock Fixing Bolts 42 31 —
Rear Seat Striker Fixing Bolts 40 30 —
Child Seat Tether Anchor Bolt 20 14 —
SUPPLEMENTAL RESTRAINT SYSTEM 9J–1
TROOPER
RESTRAINTS
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 9J–1 Service Precautions . . . . . . . . . . . . . . . . . . . 9J–29
General Description . . . . . . . . . . . . . . . . . . . . . 9J–2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–29
SRS Component And Wiring Location View . 9J–4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–30
Component Description . . . . . . . . . . . . . . . . . . 9J–4 Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . 9J–31
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–7 Service Precautions . . . . . . . . . . . . . . . . . . . 9J–31
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–31
SRS Connector Body Face Views . . . . . . . . . 9J–9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–32
Repairs And Inspections Required After SRS Coil Assembly . . . . . . . . . . . . . . . . . . . . . . 9J–34
An Accident . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–9 Service Precautions . . . . . . . . . . . . . . . . . . . 9J–34
On–Vehicle Service . . . . . . . . . . . . . . . . . . . . . . 9J–10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–34
Air Bag Assembly Handling / Shipping Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–35
/ Scrapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–11
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . 9J–37
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–20
Service Precautions . . . . . . . . . . . . . . . . . . . 9J–37
Service Precautions for SRS Component
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–24 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–37
SRS Connectors . . . . . . . . . . . . . . . . . . . . . . . . 9J–25 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J–39
Sensing And Diagnostic Module (SDM) . . . . 9J–27 Passenger Air Bag Assembly . . . . . . . . . . . . . 9J–41
Service Precautions . . . . . . . . . . . . . . . . . . . 9J–27 Service Precautions . . . . . . . . . . . . . . . . . . . 9J–41
Main Data and Specifications . . . . . . . . . . . . . 9J–42
Driver Air Bag Assembly . . . . . . . . . . . . . . . . . 9J–29

systems.
9J–2 SUPPLEMENTAL RESTRAINT SYSTEM
General Description
CAUTION: When fasteners are removed, always
reinstall them at the same location from which they
were removed. If a fastener needs to be replaced, use
the correct part number fastener for that application.
If the correct part number fastener is not available, a
fastener of equal size and strength (or stronger) may
be used. Fasteners that are not reused, and those
requiring thread locking compound will be called
out. The correct torque value must be used when
installing fasteners that require it. If the above
conditions are not followed, parts or system damage
could result.
Restraint Devices
827RW005
827RW006
Legend
(1) Deployed Air Bag
(2) Knee Bolster
(3) Seat Belt
The Supplemental Restraint System (SRS) helps

supplement the protection offered by the driver and front
passenger seat belts by deploying an air bag from the
center of the steering wheel and from the top of the right
side of the instrument panel.
The air bag deploys when the vehicle is involved in a
frontal crash of sufficient force up to 30 degrees off the
centerline of the vehicle. To further absorb the crash
energy there is a knee bolster located beneath the
instrument panel for both the driver and passenger, and
the steering column is collapsible.
System Description
The SRS consists of the Sensing and Diagnostic Module assemblies are only supplied enough current to deploy
(SDM), the driver air bag assembly, the SRS coil when the SDM detects vehicle velocity changes severe
assembly, the passenger air bag assembly and the “AIR enough to warrant deployment.
BAG” warning lamp in the instrument cluster. The SDM, The SDM contains a sensing device which converts
SRS coil assembly (driver side only), driver air bag vehicle velocity change to an electrical signal. The
assembly, passenger air bag assembly and connector electrical signal generated is processed by the SDM and
wire make up the deployment loops. The function of the then compared to a value stored in memory. When the
deployment loops is to supply current through air bag generated signal exceeds the stored value, the SDM will
assembly, which will cause deployment of the air bags in cause current to flow through the air bag assembly
the event of a frontal crash of sufficient force, up to 30 deploying the air bags.
degrees off the centerline of the vehicle. The air bag
D09RW001
SRS Component And Wiring Location View
810RW001
Legend (7) Driver Air Bag Assembly

(1) Battery (8) Starter Switch
(2) Relay & Fuse Box (9) Fuse Box, C–21
(3) Passenger Air Bag Assembly (10) SRS Body Earth
(4) SDM (11) Body Harness Connector
(5) Meter Assembly (12) Instrument Harness Connector
(6) SRS Coil Assembly (13) Engine Haness Connector
Component Description FASTENERS MUST BE CAREFULLY TORQUED AND

THE ARROW MUST BE POINTED TOWARD THE
SDM (Sensing and Diagnostic Module) FRONT OF THE VEHICLE TO ENSURE PROPER
OPERATION OF THE SRS. THE SDM COULD BE
WARNING: DURING SERVICE PROCEDURES, BE ACTIVATED WHEN POWERED WHILE NOT RIGIDLY
VERY CAREFUL WHEN HANDLING A SENSING AND ATTACHED TO THE VEHICLE WHICH COULD CAUSE
DIAGNOSTIC MODULE (SDM). NEVER STRIKE OR DEPLOYMENT AND RESULT IN PERSONAL INJURY.
JAR THE SDM. NEVER POWER UP THE SRS WHEN
The Sensing and Diagnostic Module (SDM) is designed
THE SDM IS NOT RIGIDLY ATTACHED TO THE
to perform the following functions in the SRS:
VEHICLE. ALL SDM AND MOUNTING BRACKET
1. Energy Reserve — The SDM maintains 24–Volt Loop “Air Bag” Warning Lamp
Reserve (24VLR) energy supply to provide Ignition voltage is applied to the “AIR BAG” warning lamp
deployment energy when ignition voltage is lost in a
when the ignition switch is at the ON or START positions.
frontal crash.
The SDM controls the lamp by providing ground with a
2. Frontal Crash Detection — The SDM monitors lamp driver. The “AIR BAG” warning lamp is used in the
vehicle velocity changes to detect frontal crashes SRS to do the following:
which are severe enough to warrant deployment.
1. Verify lamp and SDM operation by flashing SEVEN
3. Air Bag Deployment — When a frontal crash of (7) times when the ignition switch is first turned “ON”.
sufficient force is detected, the SDM will cause
enough current to flow through the air bag assembly 2. Warn the vehicle driver of SRS electrical system
to deploy the air bag. malfunctions which could potentially affect the
operation of the SRS. These malfunctions could
4. Malfunction Detection — The SDM performs result in nondeployment in case of a frontal crash or
diagnostic monitoring of SRS electrical components deployment for conditions less severe than intended.
and sets a diagnostic trouble code when a
The “AIR BAG ” warning lamp is the key to driver
malfunction is detected.
notification of SRS malfunctions. For proper lamp
5. Frontal Crash Recording — The SDM records operation, refer to the “SRS Diagnostic System Check” in
information regarding SRS status during frontal this section.
crash.
6. Malfunction Diagnosis — The SDM displays SRS
diagnostic trouble codes and system status
information through the use of a scan tool.
7. Driver Notification — The SDM warns the vehicle
driver of SRS malfunctions by controlling the “Air
Bag” warning lamp.
The SDM is connected to the SRS wiring harness by a
24–pin connector. This harness connector uses a
shorting clip across certain terminals in the contact area.
This shorting clip connects the “AIR BAG” warning lamp
to ground when the SDM harness connector is
disconnected or CPA (Connector Position Assurance) is
not inserted even if completely connected. This will
cause the “AIR BAG” warning lamp to come “ON” steady
whenever the ignition switch is at the ON or START
positions with the SDM disconnected.
821RW037
SRS Coil Assembly

The SRS coil assembly consists of two current carrying
coils. This is attached to the steering column and allow
rotation of the steering wheel while maintaining
continuous contact of the driver deployment loop to the
driver air bag assembly.
There is a shorting clip on the yellow 2–pin connector near
the base of steering column which connects the SRS coil
to the SRS wiring harness.
The shorting clip shorts to the SRS coil and driver air bag
assembly when the yellow 2–pin connector is
disconnected. The circuit to the driver air bag assembly is
shorted in this way to help prevent unwanted deployment
of the air bag when servicing the steering column or other
SRS components.
827RW004
Legend
(1) SDM
(2) SRS Harness
(3) Connector Position Assurance
There is a shorting clip on the passenger air bag
assembly connector which connects to the SRS harness.
The shorting clip shorts across the passenger air bag
assembly circuit when the passenger air bag assembly
connector is disconnected. The circuit to the passenger
air bag assembly is shorted in this way to help prevent
unwanted deployment of the air bag when servicing the
passenger air bag assembly, the instrument panel or
other SRS components.
825RS017
Air Bag Assemblies

The air bag assembly consist of an inflatable air bag
assembly and an inflator (a canister of gas–generating
material and an initiating device). When the vehicle is in a
frontal crash of sufficient force.
The SDM causes current flow through the deployment
loops. Current passing through the inflator ignites the
material in the air bag assembly. The gas produced from 827RS001
this reaction rapidly inflates the air bag assembly.

There is a shorting clip on the driver air bag assembly Steering Column
connector which connects the SRS coil assembly. The The steering column absorbs energy and is designed to
shorting clip shorts across the driver air bag assembly compress in a frontal crash to decrease the chance of
circuits when driver air bag assembly connector is injury to the driver.
disconnected.
The circuit to the driver air bag assembly is shorted in this
way to help prevent unwanted deployment of the air bag
when servicing the driver air bag assembly, the steering
column or other SRS components.
431RS006
Knee Bolster
The knee bolsters are used to absorb energy to protect
knees and control the forward movement of the vehicle’s
827RS008
front seat occupants during a frontal crash, by limiting leg Deployment Loops
movement. The circuits which supply current to the air bag
assemblies to deploy the air bag.
Formerly “Code”, a numerical designator used by the
SDM to indicate specific SRS malfunctions.
Driver Current Source
An output of the SDM which applies current into the driver
air bag assembly circuit during the “Initiator Assembly
Resistance Test”.
Driver Air Bag Assembly
An assembly located in the steering wheel hub consisting
of an inflatable bag, an inflator and an initiator.
EEPROM
Electrically Erasable Programmable Read Only Memory.
Memory which retains its contents when power is
removed from the SDM.
Ignition Cycle
The voltage at the SDM “Ignition 1” inputs, with ignition
740RT015
switch “ON”, is within the normal operating voltage range
for at least ten seconds before turning ignition switch
“OFF”.
Definitions
Ignition 1
Air Bag A battery voltage (B+) circuit which is only powered with
An inflatable cloth cushion designed to deploy in certain the ignition switch in the ON, or START positions.
frontal crashes. It supplements the protection offered by Initiator
the seat belts by distributing the impact load more evenly The electrical component inside the air bag assembly
over the vehicle occupant’s head and torso. which, when sufficient current flows, sets off the chemical
Asynchronous reaction that inflates the air bag.
Performed in a nonperiodic fashion, (i.e., no defined time “Initiator Assembly Resistance Test”
or interval). Tests performed once each ignition cycle when no
B+ malfunctions are detected during “Turn–ON” or
Battery voltage, (B+) The voltage available at the battery “Continuous Monitoring”. This test checks for the correct
at the time of the indicated measurement. With the key SDM configuration for the vehicle, shorts to “Ignition 1” in
“ON” and the engine not running, the system voltage will the deployment loops, high resistance or opens in the
likely be between 12 and 12.5 volts. At idle, the voltage “Driver Side High”, “Driver Side Low”, “Passenger Side
may be 14 to 16 volts. The voltage could be as low as 10 High” and “Passenger Side Low” circuits and measures
volts during engine cranking. the resistance of the inflator assembly consisting of 1)
Initiators, 2) SRS coil assembly (driver side only), 3)
Bulb Check Connectors and associated wiring.
The SDM will cause the “AIR BAG” warning lamp to flash
seven times and then go “OFF” whenever the ignition Normal Operating Voltage Range
switch transitions to the ON position from any other The voltage measured between the SDM “Ignition 1”
ignition switch position and no malfunctions are detected. terminals and “Ground” terminals is between 9 and 16
volts.
“Continuous Monitoring”
Tests performed by the SDM on the SRS every 100 Passenger Current Source
milliseconds while “Ignition 1” voltage is in the normal An output of the SDM which applies current into the
operating voltage range at the SDM. passenger air bag assembly circuit during the “Initiator
Assembly Resistance Test”.
Data Link Connector (DLC)
Formerly “DLC” a connector which allows communication Passenger Air Bag Assembly
with an external computer, such as a scan tool. An assembly located in the right side of the instrument
panel consisting of an inflatable bag, an inflator and an
Datum Line initiator.
A base line parallel to the plane of the underbody or frame
from which all vertical measurements originate. Scan Tool
An external computer used to read diagnostic information
Deploy from on–board computers via the data link connector.
To inflate the air bag.
SDM Use Of Special Tools
Sensing and Diagnostic Module which provides reserve
energy to the deployment loops, deploys the air bags WARNING: TO AVOID DEPLOYMENT WHEN
when required and performs diagnostic monitoring of all TROUBLESHOOTING THE SRS, DO NOT USE
SRS components. ELECTRICAL TEST EQUIPMENT SUCH AS A
BATTERY–POWERED OR AC–POWERED
Serial Data VOLTMETER, OHMMETER, ETC, OR ANY TYPE OF
Information representing the status of the SRS. ELECTRICAL EQUIPMENT OTHER THAN THAT
SRS SPECIFIED IN THIS MANUAL. DO NOT USE A NON
Supplemental Restraint System. POWERED PROBE–TYPE TESTER. INSTRUCTIONS
IN THIS MANUAL MUST BE FOLLOWED
SRS Coil Assembly CAREFULLY, OTHERWISE PERSONAL INJURY MAY
An assembly of two current–carrying coils in the driver RESULT. YOU SHOULD BE FAMILIAR WITH THE
deployment loop that allows the rotation of the steering TOOLS LISTED IN THIS SECTION UNDER THE
wheel while maintaining the continuous contact of the HANDLING SRS SPECIAL TOOLS.
driver deployment loop to the driver air bag assembly.
You should be able to measure voltage and resistance.
SRS Wiring Harness You should be familiar with proper use of a scan tool such
The wires and connectors that electrically connect the as the Tech 2 Diagnostic Computer, SRS
components in the SRS. Driver/Passenger Load Tool J–41433, Connector Test
“Turn–ON” Adapter Kit J–35616–A, and the DVM (Digital Multimeter)
Test which the SDM performs on the SRS once during J–39200.
each ignition cycle immediately after “Ignition 1” voltage
is applied to the SDM and before “Continuous
Monitoring”.
Diagnosis
WARNING: TO AVOID DEPLOYMENT WHEN
TROUBLESHOOTING THE SRS, DO NOT USE
ELECTRICAL TEST EQUIPMENT SUCH AS A
VOLTMETER, OHMMETER, ETC., OR ANY TYPE OF
ELECTRICAL EQUIPMENT OTHER THAN THAT
NONPOWERED PROBE–TYPE TESTER.
INSTRUCTIONS IN THIS MANUAL MUST BE
FOLLOWED CAREFULLY, OTHERWISE PERSONAL
INJURY MAY RESULT.
The “SRS Diagnostic System Check” must always be the
starting point of any SRS diagnosis. The “SRS
Diagnostic System Check” checks for proper “AIR BAG”
warning lamp operation and checks for SRS diagnostic
trouble codes using the scan tool.
1. Current diagnostic trouble codes – Malfunctions that
are presently being detected. Current diagnostic
trouble codes are stored in RAM (Random Access
Memory).
2. History diagnostic trouble codes – All malfunctions
detected since the last time the history memory was
cleared. History diagnostic trouble codes are stored
in EEPROM.
Scan Tool Diagnostics

A scan tool is used to read current and history diagnostic
trouble codes and to clear all diagnostic trouble codes
after a repair is completed. The scan tool must be
updated to communicate with the SRS through a
replaceable cartridge before it can be used for SRS
diagnostics. To use the scan tool, connect it to the data
link connector and turn the ignition switch “ON”. The scan
tool reads serial data from the SDM “Serial Data” line
terminal “24” to the data link connector terminal “9”.
SRS Connector Body Face Views
D09RW003
Legend (4) “Air Bag” Warning Lamp

(1) SDM (5) SRS Coil Assembly
(2) Driver Air Bag Assembly (6) DLC Connector
(3) Passenger Air Bag Assembly
Repairs And Inspections Required Use only new air bag assembly proper to the Trooper
which is being repaired.
After An Accident
CAUTION: Proper operation of the sensors and
NOTE: If any SRS components are damaged, they must supplemental restraint system (SRS) requires that
be replaced. If SRS component mounting points are any repairs to the vehicle structure return it to the
damaged, they must be replaced. original production configuration. Deployment
D Never use SRS parts from another vehicle. This does requires, at a minimum, replacement of the SDM, air
not include remanufactured parts purchased from an bag assembly and dimensional inspection of the
authorized dealer; they may be used for SRS repairs. steering column. Any visible damage to the SDM
mounting bracket (s) requires replacement, and the
D Do not attempt to service the SDM, the SRS coil
steering column must be dimensionally inspected,
assembly, or the air bag assembly. Service of these
whether deployment occurred or not.
items is by replacement only.
D Verify the part number of replacement air bag Accident With Deployment – Component
assembly. Replacement And Inspections
CAUTION: Never use the air bag assembly from Certain SRS components must be replaced or inspected
another vehicle and difference model year air bag for damage after a frontal crash involving air bag
assembly. deployment. Those components are:
The air bag assembly has identification colors on the D Air bag assembly
bar code label from ’00 model as follows. D SDM
Yellow color for driver air bag assembly.
White color for passenger air bag assembly.
CAUTION: Refer to “SDM Replacement Guidelines” The SDM in Driver–Passenger SRS can maintain
below for important information on SDM sufficient voltage to cause a deployment for up to 15
replacement in both deployment and non seconds after the ignition switch is turned “OFF,” the
deployment crashes. battery is disconnected, or the fuse powering the SDM is
D SRS coil assembly — Inspect wiring and connector removed.
for any signs of scorching, melting, or damage due to Many of the service procedures require removal of the
excessive heat. Replace if damaged. Refer to “C–21” fuse, and disconnection of the air bag assembly
section “SRS Coil Assembly” in this manual. from the deployment loop to avoid an accidental
deployment. If the air bag assembly is disconnected from
Accident With or Without Deployment – the deployment loop as noted in the “Disabling the SRS”
Component Inspection procedure that follows, service can begin immediately
Certain SRS system components and rotation parts must without waiting for the 15 second time period to expire.
be inspected after any crash, whether the air bag
deployed or not. Those components are: Disabling The SRS
D Steering column — Refer to Inspection Required Removal
“After an Accident” in this manual. Turn the ignition switch to “LOCK” and remove key.
D Knee bolsters and mounting points — Inspect for any 1. Remove SRS fuse C–21, from left dash side lower
distortion, bending, cracking, or other damage. fuse block or disconnect battery.
D I/P steering column reinforcement plate — Inspect for 2. Disconnect yellow 2–pin connector at the base of
any distortion, bending, cracking, or other damage. steering column.
D I/P braces — Inspect for any distortion, bending, 3. Remove glove box assembly, refer to “Passenger Air
cracking, or other damage. Bag Assembly Replacement” in this manual.
D Seat belts and mounting points — Refer to “Seat 4. Disconnect yellow 2–pin connector behind the glove
Belts” in Section “Seat Belt” of this workshop manual. box assembly.
SDM Replacement Guidelines CAUTION: With the “C–21” fuse removed and
SDM replacement policy requires replacement of SDM, ignition switch “ON”, the “AIR BAG” warning lamp
after crash involving air bag deployment when “SRS will be “ON”. This is normal operation and does not
indicate an SRS malfunction.
Warning Lamp” turn “ON”, “SRS Diagnosis” should be
done according to Section “Restraint Control System.”
Enabling The SRS
Wiring Damage Installation
If any SRS wire harness is damaged, it should be
replaced. Don’t repair SRS harness. It is replace only. CAUTION: Never use the air bag assembly from
another vehicle and difference model year air bag
SRS Connector (Plastic Body And assembly.
Terminal Metal Pin) Damage The air bag assembly has identification colors on the
bar code label from ’00 model as follows.
If any connector or terminal in the SRS wire harness Yellow color for driver air bag assembly.
(except pigtails) is damaged, it should be replaced.
SRS Wire Pigtail Damage Use only new air bag assembly proper to the Trooper
If the wiring pigtail (a wire or wires attached directly to the
Turn ignition switch to “LOCK” and remove key.
device, not by a connector) is damaged, the entire
component (with pigtail) must be replaced. Examples of 1. Connect yellow 2–pin connector passenger air bag
“pigtail” components are the driver air bag assembly, the assembly.
passenger air bag assembly, and the SRS coil assembly. 2. Install glove box assembly. Refer to “Passenger air
bag assembly replacement” in this manual.
3. Connect yellow 2–pin connector at the base of
On–Vehicle Service steering column.
Service Precaution 4. Install “AIR BAG” fuse C–21 to left dash side lower
fuse block or connect battery.
WARNING: WHEN PERFORMING SERVICE ON OR
Turn ignition switch to “ON” and verify that the “AIR BAG”
AROUND SRS COMPONENTS OR SRS WIRING,
warning lamp flashes seven times and then turns “OFF.” If
FOLLOW THE PROCEDURES LISTED BELOW TO
TEMPORARILY DISABLE THE SRS. FAILURE TO it does not operate as described, perform the “SRS
FOLLOW PROCEDURES COULD RESULT IN Diagnostic System Check” in this manual.
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL
INJURY OR OTHERWISE UNNEEDED SRS REPAIRS.
Handling / Installation / Diagnosis WIRES OR CONNECTOR ON THE UNDERSIDE OF
THE MODULE.
1. Air bag assembly should not be subjected to
temperatures above 65°C (150°F).
2. Air bag assembly, and SDM should not be used if they
have been dropped from a height of 100 centimeters
(3.28 feet) or more.
3. When a SDM is replaced, it must be oriented with the
arrow on the sensor pointing toward the front of the
vehicle. It is very important for the SDM to be located
flat on the mounting surface, parallel to the vehicle
datum line. It is important that the SDM mounting
surface is free of any dirt or other foreign material.
4. Do not apply power to the SRS unless all components
are connected or a diagnostic chart requests it, as this
will set a diagnostic trouble code.
5. The “SRS Diagnostic System Check” must be the
starting point of any SRS diagnostics. The “SRS
Diagnostic System Check” will verify proper “AIR
BAG” warning lamp operation and will lead you to the
correct chart to diagnose any SRS malfunctions.
Bypassing these procedures may result in extended
diagnostic time, incorrect diagnosis, and incorrect
parts replacement.
Air Bag Assembly Handling /

Shipping / Scrapping
Live (Undeployed) Air Bag Assembly
Special care is necessary when handling and storing a
live (undeployed) air bag assembly. The rapid gas
generation produced during deployment of the air bag 827RS044
could cause the air bag assembly, or an object in front of
the air bag assembly, to be thrown through the air in the Air Bag Assembly Shipping Procedure For
unlikely event of an accidental deployment. Live (Undeployed) Air Bag Assemblies
Service personnel should refer to the latest Service
Bulletins for proper SRS air bag assembly shipping
procedures.
Deployed Air Bag Assembly (Driver Side)

You should wear gloves and safety glasses. After the air
bag assembly has been deployed, the surface of the air
bag may contain a powdery residue. This powder
consists primarily of cornstarch (used to lubricate the bag
as it inflates) and by products of the chemical reaction.
Sodium hydroxide dust (similar to lye soap) is produced
as a by product of the deployment reaction. The sodium
hydroxide then quickly reacts with atmospheric moisture
and is converted to sodium carbonate and sodium
bicarbonate (baking soda). Therefore, it is unlikely that
sodium hydroxide will be present.
Air Bag Assembly Scrapping Procedure

827RV004
During the course of a vehicle’s useful life, certain
situations may arise which will necessitate the disposal of
WARNING: WHEN CARRYING A LIVE AIR BAG
ASSEMBLY, MAKE SURE THE BAG OPENING IS a live (undeployed) air bag assembly. This information
POINTED AWAY FROM YOU. IN CASE OF AN covers proper procedures for disposing of a live air bag
ACCIDENTAL DEPLOYMENT, THE BAG WILL THEN assembly.
DEPLOY WITH MINIMAL CHANCE OF INJURY. Before a live air bag assembly can be disposed of, it must
NEVER CARRY THE AIR BAG ASSEMBLY BY THE be deployed. A live air bag assembly must not be
disposed of through normal refuse channels.
WARNING: FAILURE TO FOLLOW PROPER NOTE: This information applies only to driver air bag
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR assembly . Refer to “Deployment Outside Vehicle
BAG ASSEMBLY DISPOSAL PROCEDURES CAN (Passenger Air Bag assembly)” in this section for
RESULT IN AIR BAG DEPLOYMENT WHICH MAY information on passenger air bag assembly scrapping.
CAUSE PERSONAL INJURY. AN UNDPLOYED AIR 1. Turn ignition switch to “LOCK”, remove key and put
BAG ASSEMBLY MUST NOT BE DISPOSED OF on safety glasses.
THROUGH NORMAL REFUSE CHANNELS. THE
UNDEPLOYED AIR BAG ASSEMBLY CONTAINS 2. Inspect J–42986 SRS Deployment Harness and
SUBSTANCES THAT CAN CAUSE SEVERE ILLNESS appropriate pigtail adapter for damage. If harness or
OR PERSONAL INJURY IF THE SEALED CONTAINER pigtail adapter is damaged, discard and obtain a
IS DAMAGED DURING DISPOSAL. DISPOSAL IN replacement.
ANY MANNER INCONSISTENT WITH PROPER 3. Short the two SRS deployment harness leads
PROCEDURES MAY BE A VIOLATION OF FEDERAL, together by fully seating one banana plug into the
STATE, AND / OR LOCAL LAW. other. SRS deployment harness shall remain shorted
and not be connected to a power source until the air
In situations which require deployment of a live air bag
bag is to be deployed.
assembly, deployment may be accomplished inside or
outside the vehicle. The method employed depends
upon the final disposition of the particular vehicle, as
noted in “Deployment Outside Vehicle” and “Deployment
Inside Vehicle” in this section.
Deployment Outside Vehicle (Driver Air

Bag Assembly)
Deployment outside the vehicle is proper when the
vehicle is to be returned to service. This includes, for
example, situations in which the vehicle will be returned to
useful service after a functionally or cosmetically deficient
air bag assembly is replaced. Deployment and disposal
of a malfunctioning air bag assembly is, of course, subject
to any required retention period.
For deployment of a live (undeployed) air bag assembly
outside the vehicle, the deployment procedure must be
followed exactly. Always wear safety glasses during this
deployment procedure until a deployed air bag assembly
is scrapped or until an undeployed air bag assembly is 827RS004
shipped. Before performing the procedures you should 4. Connect the appropriate pigtail adapter to the SRS
be familiar with servicing the SRS and with proper deployment harness.
handling of the air bag assembly. Procedures should be 5. Remove the driver air bag assembly from vehicle.
read fully before they are performed. Refer to “Inflator Module Removal” in this manual.
The following procedure requires use of J–42986 SRS
deployment harness with appropriate pigtail adapter. Do WARNING: WHEN STORING A LIVE AIR BAG
not attempt procedure without J–42986 adapter. ASSEMBLY OR WHEN LEAVING A LIVE AIR BAG
ASSEMBLY UNATTENDED ON A BENCH OR OTHER
WARNING: FAILURE TO FOLLOW PROCEDURES IN SURFACE, ALWAYS FACE THE AIR BAG AND TRIM
THE ORDER LISTED MAY RESULT IN PERSONAL COVER UP AND AWAY FROM THE SURFACE. THIS
INJURY. NEVER CONNECT DEPLOYMENT IS NECESSARY SO THAT A FREE SPACE IS
HARNESS TO ANY POWER SOURCE BEFORE PROVIDED TO ALLOW THE AIR BAG TO EXPAND IN
CONNECTING DEPLOYMENT HARNESS TO THE THE UNLIKELY EVENT OF ACCIDENTAL
DRIVER AIR BAG ASSEMBLY. DEPLOYMENT DEPLOYMENT. FAILURE TO FOLLOW
HARNESS SHALL REMAIN SHORTED AND NOT BE PROCEDURES MAY RESULT IN PERSONAL INJURY.
CONNECTED TO A POWER SOURCE UNTIL THE AIR
BAG IS TO BE DEPLOYED. THE AIR BAG
ASSEMBLY WILL IMMEDIATELY DEPLOY THE AIR
BAG WHEN A POWER SOURCE IS CONNECTED TO
IT. WEAR SAFETY GLASSES THROUGHOUT THIS
ENTIRE DEPLOYMENT AND DISPOSAL
PROCEDURE.
6. Place the driver air bag assembly on a work bench or 10. Place a power source near the shorted end of the
other surface away from all loose or flammable SRS deployment harness. Recommended
objects with its trim cover facing up, away from the application: 12 volts minimum, 2 amps minimum. A
surface. vehicle battery is suggested.
11. Connect the driver air bag assembly to the pigtail
adapter on the SRS deployment harness.
Deployment harness shall remain shorted and not be
connected to a power source until the air bag is to be
deployed. The driver air bag assembly will
immediately deploy the air bag when a power source
is connected to it.
NOTE: Ensure that the pigtail adapter is firmly seated into
the driver air bag assembly connector. Failure to fully
seat the connectors may leave the shorting bar located in
the driver air bag assembly connector functioning
(shorted) and may result in nondeployment of the driver
air bag assembly.
12. Verify that the area around the driver air bag
assembly is clear of all people and loose or flammable
objects.
13. Verify that the driver air bag assembly is resting with
its trim cover facing up.
827RV003
14. Notify all people in the immediate area that you intend
7. Clear a space on the ground about 183 cm (six feet) in to deploy the driver air bag. The deployment will be
diameter where the driver air bag assembly is to be accompanied by a substantial noise which may
deployed. A paved, outdoor location where there is startle the uninformed.
no activity is preferred. If an outdoor location is not 15. Separate the two banana plugs on the SRS
available, a space on the shop floor where there is no deployment harness.
activity and sufficient ventilation is recommended.
NOTE: When the air bag deploys, the driver air bag
Ensure no loose or flammable objects are within the
assembly may jump about 30 cm (one foot) vertically.
deployment area.
This is a normal reaction of the driver air bag to the force
of the rapid gas expansion inside the air bag.
NOTE: When the air bag deploys, the rapid gas
expansion will create a substantial noise. Notify all
people in the immediate area that you intend to deploy the
driver air bag.
WARNING: DEPLOYMENT HARNESS SHALL
REMAIN SHORTED AND NOT BE CONNECTED TO A
POWER SOURCE UNTIL THE AIR BAG IS TO BE
DEPLOYED. THE AIR BAG ASSEMBLY WILL
IMMEDIATELY DEPLOY THE AIR BAG WHEN A
POWER SOURCE IS CONNECTED TO IT.
CONNECTING THE DEPLOYMENT HARNESS TO
THE POWER SOURCE SHOULD ALWAYS BE THE
LAST STEP IN THE AIR BAG ASSEMBLY
DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW
PROCEDURES IN THE ORDER LISTED MAY RESULT
IN PERSONAL INJURY.
16. Connect the SRS deployment harness wires to the
827RV005
power source to immediately deploy the driver air
8. Place the driver air bag assembly, with its trim cover bag. Recommended application: 12 volts minimum, 2
facing up, on the ground in the space just cleared. amps minimum. A vehicle battery is suggested.
9. Stretch the SRS deployment harness and pigtail 17. Disconnect the SRS deployment harness from the
adapter from the driver air bag assembly to its full power source.
length.
18. Short the two SRS deployment harness leads
together by fully seating one banana plug into the
other.
19. In the unlikely event that the driver air bag assembly WARNING: WHEN STORING A LIVE AIR BAG
did not deploy after following these procedures, ASSEMBLY OR WHEN LEAVING A LIVE INFLATOR
proceed immediately with Steps 24 through 26. If the MODULE UNATTENDED ON A BENCH OR OTHER
driver air bag assembly did deploy, proceed with SURFACE, ALWAYS FACE THE BAG AND TRIM
Steps 20 through 23. COVER UP AND AWAY FROM THE SURFACE. THIS
20. Put on a pair of shop gloves and safety glasses to IS NECESSARY SO THAT A FREE SPACE IS
protect your hands and eyes from possible irritation PROVIDED TO ALLOW THE AIR BAG TO EXPAND IN
and heat when handling the deployed driver air bag THE UNLIKELY EVENT OF ACCIDENTAL
assembly. After the air bag assembly has been DEPLOYMENT. FAILURE TO FOLLOW
deployed, the surface of the air bag may contain a PROCEDURES MAY RESULT IN PERSONAL INJURY.
powdery residue. This power consists primarily of 26. Temporarily store the driver air bag assembly with its
cornstarch (used to lubricate the bag as it inflates) trim cover facing up, away from the surface upon
and by products of the chemical reaction. Sodium which it rests.
hydroxide dust (similar to lye soap) is produced as a
by product of the deployment reaction. The sodium Deployment Outside Vehicle (Passenger
hydroxide then quickly reacts with the atmospheric Air Bag Assembly)
moisture and is converted to sodium carbonate and
sodium bicarbonate (baking soda). Therefore, it is WARNING: FAILURE TO FOLLOW PROPER SRS AIR
unlikely that sodium hydroxide will be present after BAG ASSEMBLY DISPOSAL PROCEDURES CAN
deployment. RESULT IN AIR BAG DEPLOYMENT WHICH MAY
CAUSE PERSONAL INJURY. UNDEPLOYED AIR
WARNING: SAFETY PRECAUTIONS MUST BE BAG ASSEMBLIES MUST NOT BE DISPOSED OF
OBSERVED WHEN HANDING A DEPLOYED AIR BAG THROUGH NORMAL REFUSE CHANNELS. THE
ASSEMBLY. AFTER DEPLOYMENT, THE METAL UNDEPLOYED AIR BAG ASSEMBLY CONTAINS
SURFACES OF THE AIR BAG ASSEMBLY WILL BE SUBSTANCES THAT CAN CAUSE SEVERE ILLNESS
VERY HOT. ALLOW THE INFLATOR MODULE TO OR PERSONAL INJURY IF THE SEALED CONTAINER
COOL BEFORE HANDLING ANY METAL PORTION IS DAMAGED DURING DISPOSAL. DISPOSAL IN
OF IT. DO NOT PLACE THE DEPLOYED AIR BAG ANY MANNER INCONSISTENT WITH PROPER
ASSEMBLY NEAR ANY FLAMMABLE OBJECTS. PROCEDURES MAY BE A VIOLATION OF FEDERAL,
FAILURE TO FOLLOW PROCEDURES MAY RESULT STATE AND/OR LOCAL LAWS.
IN FIRE OR PERSONAL INJURY.
Deployment out of the vehicle is proper when the vehicle
AFTER A DRIVER AIR BAG ASSEMBLY HAS BEEN is to be returned to service. This includes, for example,
DEPLOYED, THE METAL CANISTER AND SUR- situations in which a functionally or cosmetically deficient
ROUNDING AREAS OF THE DRIVER AIR BAG AS- air bag assembly is replaced. Deployment and disposal
SEMBLY WILL BE VERY HOT. DO NOT TOUCH THE of an air bag assembly is, of course, subject to any
METAL AREAS OF THE DRIVER AIR BAG AS- required retention period.
SEMBLY FOR ABOUT TEN MINUTES AFTER DE- For deployment of a live air bag assembly out of the
PLOYMENT. IF THE DEPLOYED DRIVER AIR BAG vehicle, the deployment procedure must be followed
ASSEMBLY MUST BE MOVED BEFORE IT IS COOL, exactly. Always wear safety glasses during this
WEAR GLOVES AND HANDLE BY THE AIR BAG OR deployment procedure until the deployed air bag
TRIM COVER. assembly is scrapped. Before performing the
21. Disconnect the pigtail adapter from the driver air bag procedures, you should be familiar with servicing the SRS
assembly as soon after deployment as possible. This system and with proper handling of the air bag assembly.
will prevent damage to the pigtail adapter or SRS Procedures should be read fully before they are
deployment harness due to possible contact with the performed.
hot driver air bag assembly canister. The pigtail The following procedure requires use of J–42986 SRS
adapter can be reused. They should, however, be Deployment Harness with the appropriate pigtail adapter.
inspected for damage after each deployment and The procedure also requires the use of J–41497
replaced if necessary. Passenger Side SRS Module Deployment Fixture. Do
22. Dispose of the deployed driver air bag assembly not attempt this procedure without J–42986 and adapter,
through normal refuse channels after it has cooled for and J–41497.
at least 30 minutes. WARNING: FAILURE TO FOLLOW PROCEDURES IN
23. Wash your hands with mild soap and water afterward. THE ORDER LISTED MAY RESULT IN PERSONAL
INJURY. NEVER CONNECT DEPLOYMENT
NOTE: The remaining steps are to be followed in the HARNESS TO ANY POWER SOURCE BEFORE
unlikely event that the driver air bag assembly did not CONNECTING DEPLOYMENT HARNESS TO THE AIR
deploy after following these procedures. BAG ASSEMBLY. DEPLOYMENT HARNESS SHALL
24. Ensure that the SRS deployment harness has been REMAIN SHORTED AND NOT BE CONNECTED TO A
disconnected from the power source and that its two POWER SOURCE UNTIL THE AIR BAG IS TO BE
banana plugs have been shorted together by fully DEPLOYED. THE AIR BAG ASSEMBLY WILL
seating one banana plug into the other. IMMEDIATELY DEPLOY THE AIR BAG WHEN A
25. Disconnect the pigtail adapter from the driver air bag POWER SOURCE IS CONNECTED TO IT. WEAR
assembly. SAFETY GLASSES THROUGHOUT THIS ENTIRE
DEPLOYMENT AND DISPOSAL PROCEDURE.
NOTE: This information applies only to passenger air bag 6. Clear a space on the ground approximately 183 cm
assembly. Information for disposing of a live driver air bag (six feet) in diameter where the fixture with attached
assembly can be found in “Deployment Outside Vehicle” air bag assembly is to be placed for deployment. A
(Driver Air Bag Assembly) in this section. paved outdoor location where there is no activity is
1. Turn ignition switch to “LOCK” remove key, and put on preferred. If an outdoor location is not available, a
safety glasses. space on the shop floor where is no activity and
sufficient ventilation is recommended. Ensure that no
2. Inspect J–42986 SRS Deployment Harness and loose or flammable objects are within the deployment
appropriate pigtail adapter for damage. If harness or area.
pigtail is damaged, discard and obtain a replacement.
7. Place the J–41497 on the bench vice. This is
3. Short the two SRS Deployment Harness leads necessary to provide sufficient stabilization of the
together by fully seating one banana plug into the fixture during deployment.
other. The SRS Deployment Harness shall remain
shorted and not be connected to a power source until 8. Attach the passenger air bag assembly in the
the air bag is to be deployed. J–41497. An air bag assembly must be mounted
such that the bag will deploy upward. SECURELY
HAND–TIGHTEN ALL FASTENERS PRIOR TO
DEPLOYMENT.
827RS003
4. Connect the appropriate pigtail adapter to the SRS

Deployment Harness
901RW199
9. Stretch the SRS Deployment Harness and pigtail

adapter from the air bag assembly to its full length.
10. Place a power source near the shorted end of the
SRS deployment harness. (Recommended
application: 12 volts minimum, 2 amps minimum. A
vehicle battery is suggested.)
11. Connect the air bag assembly to the pigtail adapter on
the SRS deployment harness. The SRS Deployment
Harness shall remain shorted and not be connected
to a power source until the air bag is to be deployed.
The air bag assembly will immediately deploy the air
bag when a power source is connected to it.
NOTE: Ensure that the pigtail adapter is firmly seated into
the air bag assembly connector. Failure to fully seat the
connectors may leave the shorting bar located in the air
bag assembly connector functioning (shorting the
deployment circuit) and may result in nondeployment of
the air bag assembly.
827RS004 12. Verify that the area around the passenger air bag
5. Remove passenger air bag assembly from vehicle. assembly is clear of all people and loose or flammable
Refer to “Passenger Air Bag Assembly Removal ” in objects.
this Section 9J–3. 13. Verify that the passenger air bag assembly is firmly
and properly in J–41497.
14. Notify all people in the immediate area of your THE DEPLOYED AIR BAG ASSEMBLY MUST BE
intention to deploy the passenger air bag assembly. MOVED BEFORE IT IS COOL, WEAR GLOVES AND
The deployment will be accompanied by a substantial HANDLE BY THE AIR BAG ITSELF.
noise which may startle the uninformed.
21. Disconnect the pigtail adapter from the air bag
15. Separate the two banana plugs on the SRS assembly as soon after deployment as possible to
deployment harness. avoid damage to the pigtail adapter or SRS
NOTE: When air bag deploys, the rapid gas expansion deployment harness from contacting the hot air bag
will create a substantial noise. Notify all people in the assembly canister. The pigtail adapter and SRS
immediate area that you intend to deploy the air bag deployment harness are designed to be reused.
assembly. They should, however, be inspected for damage after
each deployment and replaced if necessary.
WARNING: DEPLOYMENT HARNESS SHALL 22. Dispose of the deployed air bag assembly through
REMAIN SHORTED AND NOT BE CONNECTED TO A normal refuse channels after it has cooled for at least
POWER SOURCE UNTIL THE AIR BAG IS TO BE 30 minutes.
DEPLOYED. THE AIR BAG ASSEMBLY WILL
IMMEDIATELY DEPLOY THE AIR BAG WHEN A 23. Wash your hands with mild soap and water afterward.
POWER SOURCE IS CONNECTED TO IT. NOTE: The remaining steps are to be followed in the
CONNECTING THE DEPLOYMENT HARNESS TO unlikely event that the air bag assembly did not deploy
THE POWER SOURCE SHOULD ALWAYS BE THE after following the above procedures.
LAST STEP IN THE AIR BAG ASSEMBLY
24. Ensure that the SRS deployment harness has been
DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW
disconnected from the power source and that its two
PROCEDURES IN THE ORDER LISTED MAY RESULT
banana plugs have been shorted together by fully
IN PERSONAL INJURY.
seating one banana plug into the other.
16. Connect the SRS deployment harness wires to the 25. Disconnect the pigtail adapter from the air bag
power source to immediately deploy the air bag assembly.
assembly. Recommended application : 12 volts
minimum, 2 amps minimum. A vehicle battery is WARNING: WHEN STORING A LIVE AIR BAG
suggested. ASSEMBLY OR WHEN LEAVING A LIVE AIR BAG
17. Disconnect the SRS deployment harness from the
SURFACE, ALWAYS FACE THE BAG UP AND AWAY
power source.
FROM THE SURFACE. THIS IS NECESSARY SO
18. Short the two SRS deployment harness leads THAT A FREE SPACE IS PROVIDED TO ALLOW THE
together by fully seating one banana plug into the AIR BAG TO EXPAND IN THE UNLIKELY EVENT OF
other. ACCIDENTAL DEPLOYMENT. FAILURE TO FOLLOW
19. In the unlikely event that the passenger air bag PROCEDURES MAY RESULT IN PERSONAL INJURY.
assembly did not deploy after following these
26. Temporarily store the air bag assembly with the bag
procedures, proceed immediately with Steps 24
facing up, away from the surface upon which it rests.
through 26. If the passenger air bag assembly
deployed as intended, proceed with Steps 20 through
23. Deployment Inside Vehicle (Vehicle
20. The passenger inflator requires no special precaution
Scrapping Procedure)
after deployment. 95% of the particulate emission are Deployment inside vehicle is proper when the vehicle is to
potassium ckloride (KLC), which is commonly sold as be destroyed or salvaged for component parts. This
an edible salt–substitutes. even if water is applied. includes, but is not limited to, the following situations:
Post deployment products are relatively pH neutral. 1. The vehicle has completed its useful life.
Disposing the inflator by burying it in a landfill will not 2. The vehicle has been damaged beyond repair in a
produce any hazardous products. As with any dusty nondeployment type accident.
environment, safety goggles, dust mask and gloves
should be worn. 3. The vehicle has been stripped or damaged beyond
repair in a theft.
WARNING: SAFETY PRECAUTIONS MUST BE 4. The vehicle will be salvaged for component parts to
OBSERVED WHEN HANDLING A DEPLOYED AIR be used on a vehicle with a different Vehicle
BAG ASSEMBLY. AFTER DEPLOYMENT, THE Identification Number (VIN) as opposed to being
METAL SURFACES OF THE AIR BAG ASSEMBLY rebuilt as same VIN. Never use SRS components
WILL BE HOT. ALLOW THE AIR BAG ASSEMBLY TO from another vehicle.
COOL BEFORE HANDLING ANY METAL PORTION
OF IT. DO NOT PLACE THE DEPLOYED INFLATOR WARNING: FAILURE TO FOLLOW PROPER SRS AIR
MODULE NEAR ANY FLAMMABLE OBJECTS. BAG ASSEMBLY DISPOSAL PROCEDURES CAN
FAILURE TO FOLLOW PROCEDURES MAY RESULT RESULT IN AIR BAG DEPLOYMENT WHICH MAY
IN FIRE OR PERSONAL INJURY. AFTER AN AIR BAG CAUSE PERSONAL INJURY. UNDEPLOYED AIR
ASSEMBLY HAS BEEN DEPLOYED, THE METAL BAG ASSEMBLIES MUST NOT BE DISPOSED OF
CANISTER AND SURROUNDING AREAS OF THE AIR THROUGH NORMAL REFUSE CHANNELS. THE
BAG ASSEMBLY WILL BE HOT. DO NOT TOUCH THE UNDEPLOYED AIR BAG ASSEMBLY CONTAINS
METAL AREAS OF THE AIR BAG ASSEMBLY FOR SUBSTANCES THAT CAN CAUSE SEVERE ILLNESS
ABOUT THIRTY MINUTES AFTER DEPLOYMENT. IF OR PERSONAL INJURY IF THE SEALED CONTAINER
IS DAMAGED DURING DISPOSAL. DISPOSAL IN STEP IN THE AIR BAG ASSEMBLY DEPLOYMENT
ANY MANNER INCONSISTENT WITH PROPER PROCEDURE.
PROCEDURES MAY BE A VIOLATION OF FEDERAL,
FAILURE TO FOLLOW PROCEDURES IN THE OR-
STATE AND/OR LOCAL LAWS.
DER LISTED COULD RESULT IN PERSONAL INJURY.
1. Turn ignition switch to “LOCK,” remove key and put 13. Disconnect passenger air bag assembly, yellow 2–pin
on safety glasses. connector located behind glove box assembly.
2. Remove all loose objects from front seats. 14. Cut the passenger air bag assembly harness
3. Disconnect driver air bag assembly, yellow 2–pin connector from the vehicle leaving at least 15 cm (six
connector located at the base of the steering column. inches) of wire at the connector.
4. Cut the driver air bag assembly yellow 2–pin harness 15. Strip 13 mm (1/2 inch) of insulation from blue–white
connector from the vehicle leaving at least 15 cm (six and pink–blue wire lead of the connector.
inches) of wire at the connector. 16. Cut two 900 cm (30 feet) deployment wires from 0.8
5. Strip 13 mm (1/2 inch) of insulation from yellow – mm@ (18 gauge) or thicker multi–strand wire. These
green and yellow – black wire lead of the connector. wires will be used to fabricate the passenger
6. Cut two 900 cm (30 feet) deployment wires from 0.8 deployment harness.
mm@ (18 gauge) or thicker multi–strand wire. These 17. Strip 13 mm (1/2 inch) of insulation from both ends of
wires will be used to fabricate the driver deployment the wires cut in the previous step.
harness. 18. Short the wires by twisting together one end from
7. Strip 13 mm (1/2 inch) of insulation from both ends of each. Deployment wires shall remain shorted and not
the wires cut in the previous step. be connected to a power source until the air bag is to
8. Short the wires by twisting together one end from be deployed.
each. Deployment wires shall remain shorted and not WARNING: FAILURE TO FOLLOW PROCEDURES IN
be connected to a power source until the air bag is to THE ORDER LISTED COULD RESULT IN PERSONAL
be deployed. INJURY. NEVER CONNECT DEPLOYMENT WIRES
WARNING: FAILURE TO FOLLOW PROCEDURES IN TO ANY POWER SOURCE BEFORE CONNECTING
THE ORDER LISTED COULD RESULT IN PERSONAL DEPLOYMENT WIRES TO THE AIR BAG ASSEMBLY
INJURY. NEVER CONNECT DEPLOYMENT WIRES LEADS. DEPLOYMENT WIRES SHALL REMAIN
TO ANY POWER SOURCE BEFORE CONNECTING SHORTED AND NOT BE CONNECTED TO A POWER
DEPLOYMENT WIRES TO THE AIR BAG ASSEMBLY SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED.
LEADS. DEPLOYMENT WIRES SHALL REMAIN THE AIR BAG ASSEMBLY WILL IMMEDIATELY
SHORTED AND BE NOT CONNECTED TO A POWER DEPLOY THE AIR BAG WHEN A POWER SOURCE IS
SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. CONNECTED TO IT. WEAR SAFETY GLASSES
THE AIR BAG ASSEMBLY WILL IMMEDIATELY THROUGHOUT THIS ENTIRE DEPLOYMENT AND
DEPLOY THE AIR BAG WHEN A POWER SOURCE IS DISPOSAL PROCEDURE.
CONNECTED TO IT. WEAR SAFETY GLASSES 19. Twist together one connector wire lead to one
THROUGHOUT THIS ENTIRE DEPLOYMENT AND deployment wire. The connection should be
DISPOSAL PROCEDURE. mechanically secure.
9. Twist together one connector wire lead to one 20. Bend twisted connection made in the previous step
deployment wire. The connection should be flat and wrap tightly with electrical tape to insulate and
mechanically secure. secure.
10. Bend twisted connection made in the previous step 21. Twist together, bend and tape the remaining
flat and wrap tightly with electrical tape to insulate and connector wire lead to the remaining deployment
secure. wire.
11. Twist together, bend and tape the remaining 22. Connect the deployment harness to the passenger air
connector wire lead to the remaining deployment bag assembly, yellow 2–pin connector located behind
wire. the glove box assembly. Route deployment harness
12. Connect the deployment harness to the driver air bag out the passenger side of the vehicle.
assembly, yellow 2–pin connector at the base of the WARNING: DEPLOYMENT WIRES SHALL REMAIN
steering column. Route deployment harness out the SHORTED AND NOT BE CONNECTED TO A POWER
driver side of the vehicle. SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED.
WARNING: DEPLOYMENT WIRES SHALL REMAIN THE AIR BAG ASSEMBLY WILL IMMEDIATELY
SHORTED AND NOT BE CONNECTED TO A POWER DEPLOY THE AIR BAG WHEN A POWER SOURCE IS
SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. CONNECTED TO IT. CONNECTING THE
DEPLOYMENT WIRES SHOULD ALWAYS BE THE
THE AIR BAG ASSEMBLY WILL IMMEDIATELY FINAL STEP IN THE AIR BAG ASSEMBLY
DEPLOY THE AIR BAG WHEN A POWER SOURCE IS DEPLOYMENT PROCEDURE. FAILURE TO FOLLOW
CONNECTED TO IT. PROCEDURES IN THE ORDER LISTED COULD
CONNECTING THE DEPLOYMENT WIRES TO THE RESULT IN PERSONAL INJURY.
POWER SOURCE SHOULD ALWAYS BE THE FINAL
23. Verify that the inside of the vehicle and the area 30. Connect the passenger deployment harness wires to
surrounding the vehicle are clear of all people and a power source to immediately deploy the passenger
loose or flammable objects. air bag assembly. Recommended application: 12
24. Stretch the driver and passenger deployment volts minimum, 2 amps minimum. A vehicle battery is
harness to their full length. suggested.(Driver air bag assembly) Put on a pair of
shop gloves and safety glasses to protect your hands
25. Completely cover windshield area and front door
and eyes from possible irritation and heat when
window openings with a drop cloth, blanket or similar
handling the deployed air bag assembly. After an air
item. This reduces the possibility of injury due to
bag assembly has been deployed, the surface of the
possible fragmentation of the vehicle’s glass or
air bag may contain a powdery residue. This powder
interior.
consists primarily of cornstarch (used to lubricate the
26. Notify all people in the immediate area that you intend bag as it inflates) and by products of the chemical
to deploy the air bags. The deployment will be reaction. Sodium hydroxide dust (similar to lye soap)
accompanied by a substantial noise which may is produced as a by product of the deployment
startle the uninformed. reaction. The sodium hydroxide then quickly reacts
27. Separate the two ends of the driver deployment with atmospheric moisture and is converted to
harness wires. sodium carbonate and sodium bicarbonate (baking
soda). Therefore, it is unlikely that sodium hydroxide
WARNING: DEPLOYMENT WIRES SHALL REMAIN will be present after deployment.(Passenger air bag
SHORTED AND NOT BE CONNECTED TO A POWER assembly) The passenger inflator requires no special
SOURCE UNTIL THE AIR BAG IS TO A POWER precaution after deployment. 95% of the particulate
SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED. emission are potassium chloride (KLC), which is
THE AIR BAG ASSEMBLY WILL IMMEDIATELY commonly sold as an edible salt–substitutes. even if
DEPLOY THE AIR BAG WHEN A POWER SOURCE IS water is applied. Post deployment products are
CONNECTED TO IT. CONNECTING THE relatively pH neutral. Disposing the inflator by burying
DEPLOYMENT WIRES TO THE POWER SOURCE it in a landfill will not products any hazardous
SHOULD ALWAYS BE THE FINAL STEP IN THE AIR products. As with any dusty environment, safety
BAG ASSEMBLY DEPLOYMENT PROCEDURE. goggles, dust mask and gloves should be worn.
FAILURE TO FOLLOW PROCEDURES IN THE
ORDER LISTED COULD RESULT IN PERSONAL WARNING: SAFETY PRECAUTIONS MUST BE
INJURY. OBSERVED WHEN HANDLING A DEPLOYED AIR
BAG ASSEMBLY. AFTER DEPLOYMENT, THE
NOTE: When the air bag deploys, the rapid gas METAL SURFACES OF THE AIR BAG ASSEMBLY
expansion will create a substantial noise. Notify all WILL BE VERY HOT. ALLOW THE AIR BAG
people in the immediate area that you intend to deploy the ASSEMBLY TO COOL BEFORE HANDLING ANY
air bags. METAL PORTION OF IT. DO NOT PLACE THE HOT
28. Connect the driver deployment harness wires to a DEPLOYED AIR BAG ASSEMBLY NEAR ANY
power source to immediately deploy the driver air bag FLAMMABLE OBJECTS. FAILURE TO FOLLOW
assembly. Recommended application: 12 volts PROCEDURES COULD RESULT IN FIRE OR
minimum, 2 amps minimum. A vehicle battery is PERSONAL INJURY.
suggested. After an air bag assembly has been deployed, the
29. Separate the two ends of the passenger deployment metal canister and surrounding areas of the air bag
harness wires. assembly will be very hot. Do not touch the metal
areas of the air bag assembly for about 30 minutes
WARNING: DEPLOYMENT WIRES SHALL REMAIN after deployment. If the deployed air bag assembly
SHORTED AND NOT BE CONNECTED TO A POWER must be moved before it is cool, wear gloves and
SOURCE UNTIL THE AIR BAG IS TO A POWER handle by the air bag or trim cover.
SOURCE UNTIL THE AIR BAG IS TO BE DEPLOYED.
THE AIR BAG ASSEMBLY WILL IMMEDIATELY 31. Short the driver deployment harness wires by twisting
DEPLOY THE AIR BAG WHEN A POWER SOURCE IS together one end from each. Repeat this procedure
CONNECTED TO IT. CONNECTING THE for the passenger deployment harness.
DEPLOYMENT WIRES TO THE POWER SOURCE 32. Carefully remove drop cloth from vehicle and clean off
SHOULD ALWAYS BE THE FINAL STEP IN THE AIR any fragments or discard drop cloth entirely.
BAG ASSEMBLY DEPLOYMENT PROCEDURE. 33. Disconnect driver deployment harness and
FAILURE TO FOLLOW PROCEDURES IN THE passenger deployment harness from vehicle and
ORDER LISTED COULD RESULT IN PERSONAL discard.
INJURY.
34. In the unlikely event that either or both of the air bag
assemblies did not deploy after following these
procedures, proceed immediately with Steps 36
through 37. If the air bag assembly deployed, proceed
to step 35.
35. With both air bags deployed, the vehicle may be
scrapped in the same manner as a non–SRS
equipped vehicle.
NOTE: The remaining steps are to be followed in the
unlikely event that the air bag assembly did not deploy
after following these procedures.
36. Remove the undeployed air bag assembly (s) from
the vehicle. For driver air bag assembly refer to in the
“Passenger Air Bag Assembly Removal” in this
manual.
WARNING: WHEN STORING A LIVE AIR BAG
ASSEMBLY OR WHEN LEAVING A LIVE AIR BAG
SURFACE, ALWAYS FACE THE BAG AND TRIM
COVER UP, AWAY FROM THE SURFACE. THIS IS
NECESSARY SO THAT A FREE SPACE IS PROVIDED
TO ALLOW THE AIR BAG TO EXPAND IN THE
UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT.
FAILURE TO FOLLOW PROCEDURES COULD
RESULT IN PERSONAL INJURY.
37. Temporarily store the air bag assembly with the air
bag opening facing up, away from the surface upon
which it rests.
Deployed Air Bag Assembly Handling

Put on a pair of shop gloves and safety glasses to protect
your hands and eyes from possible irritation and heat
when handling the deployed air bag assembly.
After the air bag assembly has been deployed, the
surface of the air bag may contain a powdery residue.
This powder consists primarily of cornstarch (used to
lubricate the bag as it inflates) and by products of the
chemical reaction. Sodium hydroxide dust (similar to lye
soap) is produced as a by product of the deployment
reaction. The sodium hydroxide then quickly reacts with
atmospheric moisture and is converted to sodium
carbonate and sodium bicarbonate (baking soda).
Therefore, it is unlikely that sodium hydroxide will be
present after deployment.
Special Tools
WARNING: TO AVOID DEPLOYMENT WHEN J–39200 DVM
TROUBLESHOOTING THE SRS, DO NOT USE
ELECTRICAL TEST EQUIPMENT SUCH AS A
VOLTMETER, OHMMETER, ETC., OR ANY TYPE OF
ELECTRICAL EQUIPMENT OTHER THAN THAT
NONPOWERED PROBE–TYPE TESTER.
INSTRUCTIONS IN THIS MANUAL MUST BE
FOLLOWED CAREFULLY, OTHERWISE PERSONAL
INJURY MAY RESULT.
J–41433 SRS Driver/Passenger Load Tool
901RS153
The J–39200 DVM is the preferred DVM for use in SRS

diagnosis and repair. However, J–34029—A may be
used if J–39200 is not available. No other DVMs are
approved for SRS diagnosis and repair.
Scan Tool
901RS146
The SRS Driver/Passenger Load Tool J–41433 is used

only when called for in this section. It is used as a
diagnostic aid and safety device to prevent inadvertent air
bag assembly deployment.
The load tool has three yellow connectors attached to its
case.
The three small connectors are electrically functional and
serve as resistive load substitutions.
No more than two connectors are used at any time. One
of the small connectors is used to substitute for the load of
the driver air bag assembly when it is connected at the top
of the column to the SRS coil assembly. Another small
connector is used to substitute for the load of the driver air
bag assembly and the SRS coil assembly when it is
connected at the base of the column to the SRS wiring 901RW176
harness. The third small connector is used to substitute The Tech 2 is used to read and clear SRS Diagnostic
for the load of the passenger air bag assembly when Trouble Codes (DTCs). Refer to the Tech 2 Operators,
connected to the passenger air bag assembly harness Manual for specific information on how to use the Tech 2.
connector.
By substituting the resistance of the load tool when called
for, a determination can be made as to whether an inflator
circuit component is causing system malfunction and
which component is causing the malfunction. The load
tool should be used only when specifically called for in the
diagnostic procedures.
J–35616—A Connector Test Adapter Kit J–41497 SRS Deployment Fixture
901RS151 901RW199
The J–35616–A Connector Test Adapter Kit must be used The J–41497 SRS Deployment Fixture must be used for
whenever a diagnostic procedure requests checking or deployment of the undeployed passenger side air bag.
probing a terminal. Using the appropriate adapter will
ensure that no damage to the terminal will occur from the J–42987 SRS Adapter for Load Tool.
DVM prove, such as spreading or bending. The adapter
will also give an idea of whether contact tension is
sufficient, helping to find an open or intermittent open due
to poor terminal contact.
J–42986 SRS Deployment Tool
901RW107
The J–42987 SRS Adapter for Load Tool must be used

with J–41433 SRS Driver/Passenger Load Tool.
901RW106
The J–42986 SRS Deployment Tool must be used for

deployment of the undeployed air bag.
Tech 2 Scan Tool
tool user guide.
740RW060
6. Turn on the vehicle ignition switch.

901RW200
Legend
(1) PCMCIA Card
(2) RS 232 Loop Back Connector
(4) DLC Cable
(5) Tech–2
Getting Started
D Before operating the Isuzu PCMCIA card with the
Tech 2, the following steps must be performed:
1. Insert the Isuzu 98 System PCMCIA card (1) into the
Tech 2 (5).
(4).
3. Connect the DLC cable to the Tech 2 (5) 060RW009
4. Make sure of the vehicle ignition is off. NOTE: The RS232 Loop back connector is only used to
5. Connect the Tech 2 SAE 16/19 adapter to the vehicle diagnosis Tech 2. Refer to user guide of the Tech 2.
ALDL/DLC connector.
Operating Procedure
The power up screen is displayed when you power up the
tester with the Isuzu systems PCMCIA card. Follow the
operating procedure below.
060RW019
060RY027
Service Precautions for SRS 3. Connect yellow 2–pin connector at the base of the
steering column.
Component Service 4. Install “AIR BAG” fuse “C–21” to left dash side lower
CAUTION: When fasteners are removed, always fuse block or connect battery.
reinstall them at the same location from which they Turn ignition switch to “ON” and verify that the “AIR BAG”
were removed. If a fastener needs to be replaced, use warning lamp flashes seven times and then turns “OFF.” If
the correct part number fastener for that application. it does not operate as described, perform the “SRS
If the correct part number fastener is not available, a Diagnostic System Check” in this section.
fastener of equal size and strength (or stronger) may
be used. fasteners that are not reused, and those Handling / Installation / Diagnosis
requiring thread locking compound will be called 1. Air bag assembly should not be subjected to
out. The correct torque value must be used when temperatures above 65°C (150°F).
installing fasteners that require it. If the above
conditions are not followed, parts or system damage 2. Air bag assembly, and SDM should not be used if they
could result. have been dropped from a height of 100 centimeters
(3.28 feet) or more.
WARNING: WHEN PERFORMING SERVICE ON OR 3. When a SDM is replaced, it must be oriented with the
AROUND SRS COMPONENTS OR SRS WIRING, arrow on the SDM pointing toward the front of the
FOLLOW THE PROCEDURES LISTED BELOW TO vehicle. It is very important for the SDM to be located
TEMPORARILY DISABLE THE SRS. FAILURE TO flat on the mounting surface, parallel to the vehicle
FOLLOW PROCEDURES COULD RESULT IN datum line. It is important that the SDM mounting
POSSIBLE AIR BAG DEPLOYMENT, PERSONAL surface is free of any dirt or other foreign material.
INJURY OR OTHERWISE UNNEEDED SRS REPAIRS.
4. Do not apply power to the SRS unless all components
The SDM in Driver–Passenger SRS can maintain are connected or a diagnostic chart requests it, as
sufficient voltage to cause a deployment for up to 15 this will set a diagnostic trouble code.
seconds after the ignition switch is turned “OFF,” the
battery is disconnected, or the fuse powering the SDM is 5. The “SRS Diagnostic System Check” must be the
removed. starting point of any SRS diagnostics. The “SRS
Many of the service procedures require removal of the Diagnostic System Check” will verify proper “AIR
“C–21” fuse, and disconnection of the air bag assembly BAG” warning lamp operation and will lead you to the
from the deployment loop to avoid an accidental correct chart to diagnose any SRS malfunctions.
deployment. If the air bag assembly is disconnected from Bypassing these procedures may result in extended
the deployment loop as noted in the “Disabling the SRS” diagnostic time, incorrect diagnosis, and incorrect
procedure that follows, service can begin immediately parts replacements.
without waiting for the 15 second time period to expire.
Inspections Required After An Accident
Disabling The SRS
CAUTION: Certain SRS components must be
Removal replaced after a frontal crash involving air bag
Turn the ignition switch to “OFF” and turn the steering deployment.
wheel so that the vehicle’s wheels are pointing straight In all types of accidents regardless of “Air Bag”
ahead. deployment, visually inspect all of the following
1. Remove SRS fuse “C–21” from left dash side lower components and replace as required:
fuse block or disconnect battery. — Driver air bag assembly
2. Disconnect yellow 2–pin connector at the base of — Passenger air bag assembly
steering column. — Steering wheel
3. Remove glove box assembly; Refer to “Passenger air — SRS coil assembly
bag assembly replacement” in this section. — Steering column
4. Disconnect passenger air bag assembly yellow 2–pin — Knee bolster and instrument panel mounting
connector behind the glove box assembly. attachments
CAUTION: With the “C–21” fuse removed and — Driver seat and belt
ignition switch “ON,” the “AIR BAG” warning lamp — Passenger seat and belt
will be “ON.” This is normal operation and does not
indicate an SRS malfunction. — SDM
SDM always should be checked according to “SDM
Enabling The SRS Replacement Guidelines.”
Installation CAUTION: Refer to “SDM Replacement Guidelines”
Turn ignition switch to “LOCK” and remove key. below for important information on SDM
replacement in both deployment and
1. Connect yellow 2–pin connector passenger air bag non–deployment crashes.
assembly.
Inspect SRS coil assembly wiring and steering wheel for
2. Install glove box assembly. Refer to “Passenger Air any sign of scorching, melting, or damage due to
Bag Assembly Replacement” in this section. excessive heat. If coil assembly wire or steering wheel is
damaged, replace them. The steering column and wheel Removal
must be dimensionally checked to determine if they are To remove the connector, hold the cover insulator (1) and
damaged. Refer to steering wheel of in this manual. pull it. The cover insulator slides and lock will be released.
Never use SRS parts from another vehicle. This does not Do not hold the socket insulator (2).
include remanufactured parts purchased from an
authorized Isuzu Retailer; they may be used for SRS
repairs.
Do not attempt to repair the SDM, the SRS harness, the
SRS coil assembly, the air bag assembly, the steering
wheel, or the steering column. Service of these items is
replacement only. Verify replacement part numbers.
CAUTION: Proper operation of the SDM and
supplemental restraint system (SRS) requires that
any repairs to the vehicle structure return it to its
original production configuration.
SRS Connectors
CAUTION: The special yellow color connectors are
used for supplemental restraint system-air bag circuit.
When removing the oable harnese, do not pull the cables
otherwile, cable disconnection may occur. When connect
the SRS connector, insert the connector completely.
Imperfect locking may cause malfunction of SRS circuit.
827RW028
Installation
To install the connector, hold the socket insulator (1) and
insert it. The cover insulator slides and connector will be
locked. Do not hold the cover insulator (2).
827RW027
Sensing And Diagnostic Module (SDM)

Service Precautions 5. Remove the three SDM fixing bolts and remove SDM.
WARNING: DURING SERVICE PROCEDURES, BE

VERY CAREFUL WHEN HANDLING SDM. NEVER
STRIKE OR JAR SDM. UNDER SOME
CIRCUMSTANCES, IT COULD CAUSE
DEPLOYMENT AND RESULT IN PERSONAL INJURY
OR IMPROPER OPERATION OF THE
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) . SDM
MOUNTING BRACKET BOLTS MUST BE
CAREFULLY TORQUED TO ASSURE PROPER
OPERATION. NEVER POWER UP THE SRS WHEN
SDM IS NOT RIGIDLY ATTACHED TO THE VEHICLE.
THE SDM COULD BE ACTIVATED WHEN POWERED
WHILE NOT RIGIDLY ATTACHED TO THE VEHICLE
WHICH COULD CAUSE DEPLOYMENT AND RESULT
IN PERSONAL INJURY.
WARNING: PROPER OPERATION OF THE SENSING
AND DIAGNOSTIC MODULE (SDM) REQUIRES THE
SDM TO BE RIGIDLY ATTACHED TO THE VEHICLE
STRUCTURE AND THAT THE ARROW ON THE 827RW026
SENSOR BE POINTING TOWARD THE FRONT OF

THE VEHICLE. Legend
(1) SDM
SDM is specifically calibrated and is keyed to the SDM (2) SRS Harness
location SRS wiring harness. Caution should be used to
ensure proper location of the SDM. The keying of the (3) Connector Position Assurance
SDM to its location and wiring harness connectors should
never be modified in the field.
Installation
Removal 1. Install the SDM on bracket and fixing bolts and tighten
the fixing bolts to the specified torque.
1. Disable the SRS (Refer to “Disabling the SRS” in this
section). Torque: 10 N·m (87 lb in)
2. Remove the transmission knob (for M/T) and transfer 2. Connect the SDM harness connector and after that,
lever knob. put CPA into connector.
3. Remove the front console assembly and disconnect 3. Install the front console.
wiring harness connector. 4. Install the transmission knob (for M/T) and transfer
4. Pull CPA (Connector Position Assurance) out and lever knob.
push connector lock down to disconnect the SDM
harness connector.
5. Enable the SRS (Refer to “Enabling the SRS” in this
section).
827RW026
Legend
(1) SDM
(2) SRS Harness
(3) Connector Position Assurance
Driver Air Bag Assembly

Service Precautions Removal
WARNING: SAFETY PRECAUTIONS MUST BE 1. Disable the SRS (Refer to “Disabling the SRS” in this
FOLLOWED WHEN HANDLING A DEPLOYED AIR section).
BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR 2. Loosen the air bag assembly fixing bolts from behind
BAG ASSEMBLY SURFACE MAY CONTAIN A SMALL the steering wheel assembly using a TORX driver or
AMOUNT OF SODIUM HYDROXIDE, A BY–PRODUCT equivalent until the air bag assembly can be released
OF THE DEPLOYMENT REACTION, THAT IS from steering wheel.
IRRITATING TO THE SKIN AND EYES. MOST OF THE
POWER ON THE AIR BAG ASSEMBLY IS
HARMLESS. AS A PRECAUTION, WEAR GLOVES
AND SAFETY GLASSES WHEN HANDLING A
DEPLOYED AIR BAG ASSEMBLY, AND WASH YOUR
HANDS WITH MILD SOAP AND WATER
AFTERWARDS.
ASSEMBLY, MAKE SURE THE BAG AND TRIM
COVER ARE POINTED AWAY FROM YOU. NEVER
CARRY AIR BAG ASSEMBLY BY THE WIRES OR
CONNECTOR ON THE UNDERSIDE OF MODULE. IN
THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE
BAG WILL THEN DEPLOY WITH MINIMAL CHANCE
OF INJURY. WHEN PLACING ALIVE AIR BAG
ASSEMBLY ON A BENCH OR OTHER SURFACE,
ALWAYS FACE BAG AND TRIM COVER UP, AWAY
FROM THE SURFACE. NEVER REST A STEERING
COLUMN ASSEMBLY ON THE STEERING WHEEL
WITH THE AIR BAG ASSEMBLY FACE DOWN AND 827RT008
COLUMN VERTICAL. THIS IS NECESSARY SO THAT 3. Disconnect the yellow 2–pin connector located
A FREE SPACE IS PROVIDED TO ALLOW THE AIR behind the air bag assembly and remove air bag
BAG ASSEMBLY TO EXPAND IN THE UNLIKELY assembly. Refer to “SRS Connectors” in this section
EVENT OF ACCIDENTAL DEPLOYMENT. for removal and installation.
OTHERWISE, PERSONAL INJURY COULD RESULT.
NOTE: In the event deployment has occurred, inspect
coil assembly wire for any signs of scorching, melting or
any other damage due to excessive heat. If the coil has
been damaged, replace it.
827RT009
Installation
1. Connect air bag to wiring harness connector.
cover (wire protector) of air bag to prevent lead wire from
being pinched.
827RT009
2. Install air bag into steering wheel and tighten bolts to

specified sequence as shown in figure.
CAUTION: Never use the air bag assembly from
assembly.
The air bag assembly has identification colors on the
Use only new air bag assembly proper to the Trooper
827RW007

section).
Steering Wheel
Service Precautions
WARNING: SAFETY PRECAUTIONS MUST BE
FOLLOWED WHEN HANDLING A DEPLOYED AIR
BAG ASSEMBLY. AFTER DEPLOYMENT, THE AIR
BAG ASSEMBLY SURFACE MAY CONTAIN A SMALL
AMOUNT OF SODIUM HYDROXIDE, A BY–PRODUCT
OF THE DEPLOYMENT REACTION, THAT IS
AFTERWARDS.
CONNECTOR ON THE UNDERSIDE OF MODULE. IN 827RT008
THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE 3. Disconnect the yellow 2–pin connector located
BAG WILL THEN DEPLOY WITH MINIMAL CHANCE behind the air bag assembly and remove air bag
OF INJURY. WHEN PLACING ALIVE AIR BAG assembly.Refer to “SRS Connectors” in this section
ASSEMBLY ON A BENCH OR OTHER SURFACE, for removal and installation.
ALWAYS FACE BAG AND RIM COVER UP, AWAY 4. Disconnect horn lead.
WITH THE AIR BAG ASSEMBLY FACE DOWN AND
COLUMN VERTICAL. THIS IS NECESSARY SO THAT
A FREE SPACE IS PROVIDED TO ALLOW THE AIR
BAG ASSEMBLY TO EXPAND IN THE UNLIKELY
Removal
section).
2. Loosen the air bag assembly fixing bolts from behind
the steering wheel assembly using a TORX driver or
827RT009
equivalent until the air bag assembly can be released
from steering wheel. 5. Remove steering wheel attachment nut.
6. Apply a setting mark across the steering wheel and Installation
shaft so parts can be reassembled in their original
position. 1. Install the steering wheel and align the setting marks.
430RS004 430RS004
7. Move the tires to the straight ahead position before 2. Tighten the steering wheel fixing nut to the specified
removing the steering wheel. Install steering wheel torque.
puller onto steering wheel and remove steering wheel Torque : 34 N · m (25 lb·ft)
with J–29752.
4. Connect air bag to wiring harness connector.
cover (wire protector) of air bag to prevent lead wire from
being pinched.
430RT009
8. Feed wiring through the wheel and remove wheel.

wheel. The steering shaft is designed as an energy 827RT009
absorbing unit.
specified sequence as show in figure.
CAUTION: Never use the air bag assembly from
assembly.
827RT008

section).
SRS Coil Assembly

Service Precautions
AFTERWARDS.
ALWAYS FACE BAG AND RIM COVER UP, AWAY 4. Disconnect horn lead connector.
Removal
section).
2. Loosen the air bag assembly fixing bolts from behind
the steering wheel assembly using a TORX driver or
827RT009
from steering wheel.
5. Remove the steering wheel attachment nut. 12. Remove air conditioning lower duct.
6. Apply a setting mark across the steering wheel and 13. Disconnect the 2–pin wiring harness connectors
shaft so parts can be reassembled in their original located at the base of steering column.
position.
in the direction of the shaft by using a hammer or
other impact tools in an attempt to remove the
steering wheel. The steering shaft is designed as an
energy absorbing unit.
coil.
NOTE: SRS coil is a part of combination switch
assembly, which cannot be replaced separately.
Installation
1. Install the combination switch assembly with SRS
coil.
about 3 turns and align the neutral mark (1).
430RS004
7. Move the tires to the straight ahead position before
felt. Forced further turning may damage the cable in
removing the steering wheel and remove wheel with
the SRS coil.
J–29752.
826RW014
430RT009
3. Connect the wiring harness connectors located at the
8. Feed wiring though the wheel and remove wheel.
base of steering column.
9. Remove the steering lower cover and engine hood
4. Install the air conditioning lower duct.
opening lever.
5. Install the steering column cover.
10. Remove the driver knee bolster assembly.
11. Remove the steering column cover.
CAUTION: When installing the steering column 11. Connect air bag to wiring harness connector.
cover, be sure to wire (through each harness) as
illustrated so that the harness starter switch,
cover (wire protector) of air to prevent lead wire from
combination switch and SRS coil may not catch
being pinches.
wiring.
827RT009
825RS048
6. Install the driver knee bolster assembly. 12. Install air bag into steering wheel and tighten bolts to
7. Install the steering lower cover and engine hood
opening lever. Torque: 8 N·m (69 lb in)
8. Install the steering wheel and align the setting marks. CAUTION: Never use the air bag assembly from
assembly.
430RS004

torque.
Torque: 34 N·m (25 lb·ft)
827RT0008

section).
Steering Column
Service Precautions
AFTERWARDS.
ALWAYS FACE BAG AND RIM COVER UP, AWAY
Removal
1. Disable the SRS (Refer to “Disabling the SRS ” in this
section).
2. Loosen the air bag assembly fixing bolts from behind 827RT009
the steering wheel assembly using a TORX driver or 4. Disconnect horn lead connector.
from steering wheel. 5. Remove the steering wheel attachment nut.
6. Apply a setting mark across the steering wheel and 9. Remove the steering lower cover and engine hood
shaft so parts can be reassembled in their original opening lever.
position. 10. Remove the driver knee bolster assembly.
430RS004
740RT015
7. Move the tires to the straight ahead position before 11. Remove the steering column cover.
removing the steering wheel and removing wheel with
12. Remove air conditioning lower duct.
J–29752.
13. Disconnect the wiring harness connectors located at
the base of steering column.
absorbing unit.
coil.
NOTE: SRS coil is a part of combination switch
assembly, which cannot be replaced separately.
16. Remove the cushion rubber.
17. Disconnect shift lock cable (A/T only).
18. Disconnect the starter switch harness connector
located base of steering column.
430RT009
19. Remove steering lock cylinder assembly.
8. Feed wiring though the wheel and remove wheel.
20. Apply a setting mark across the universal joint and 7. Install cushion rubber.
steering shaft to reassemble the parts in their original 8. Install snap ring.
position.
9. Install the combination switch assembly with SRS
coil.
10. Connect the wiring harness connector located on the
base of steering column.
about 3 turns and align the neutral mark (1).
in the SRS coil.
431RS013
21. Remove steering column assembly.
Installation
1. Install the steering column assembly and align the
setting marks on the universal joint and steering shaft
made during removal.
826RW014
12. Install steering column cover.

CAUTION: When installing the steering column
cover, be sure to wire (through each harness) as
illustrated so that the harness starter switch,
combination switch and SRS coil may not catch
wiring.
431RS013
2. Tighten the steering column fixing bolts (dash panel

side) to the specified torque.
3. Tighten the steering column fixing bolts (Pedal
bracket) to the specified torque.
Torque: 31 N·m (23 lb ft) 825RS048
5. Install steering lock cylinder assembly.

6. Connect shift lock cable (For A/T)
13. Install the steering wheel and align the setting marks. CAUTION: Never use the air bag assembly from
assembly.
430RS004

torque.
16. Connect air bag wiring harness connector.
cover (wire protector) of air bag to prevent lead wire from 827RT008
being pinched. 18. Enable the SRS (Refer to “Enabling the SRS” in this
section).
827RT009
Passenger Air Bag Assembly

Service Precautions Removal
AFTERWARDS.
CONNECTOR ON THE UNDERSIDE OF MODULE. IN
THE CASE OF AN ACCIDENTAL DEPLOYMENT, THE
BAG WILL THEN DEPLOY WITH MINIMAL CHANCE 827RS001
OF INJURY. WHEN PLACING ALIVE AIR BAG 1. Disable the SRS (Refer to “Disabling the SRS ” in this
ASSEMBLY ON A BENCH OR OTHER SURFACE, section).
ALWAYS FACE BAG AND RIM COVER UP, AWAY 2. Remove gear control knob.
FROM THE SURFACE. NEVER REST A STEERING 3. Remove front console assembly.
WITH THE AIR BAG ASSEMBLY FACE DOWN AND 4. Remove rear console assembly and disconnect
COLUMN VERTICAL. THIS IS NECESSARY SO THAT harness connector.
A FREE SPACE IS PROVIDED TO ALLOW THE AIR 5. Remove ECM and SDM cover.
BAG ASSEMBLY TO EXPAND IN THE UNLIKELY 6. Remove glove box assembly with lid.
EVENT OF ACCIDENTAL DEPLOYMENT. 7. Remove glove box cover.
8. Remove instrument panel assist side lower cover.
NOTE: IN THE EVENT DEPLOYMENT HAS 9. Disconnect engine hood opener lever.
OCCURRED, INSPECT COIL ASSEMBLY WIRE FOR 10. Remove instrument panel door side lower cover.
ANY SIGNS OF SCORCHING, MELTING OR ANY
OTHER DAMAGE DUE TO EXCESSIVE HEAT. IF THE 11. Remove lower cluster with ashtray.
COIL HAS BEEN DAMAGED, REPLACE IT. 12. Remove meter cluster assembly and disconnect
harness connector.
13. Remove instrument panel lower center cover.
14. Disconnect passenger air bag assembly harness
connector.
15. Remove air bag assembly fixing bolts and nuts.
16. Remove passenger air bag assembly.
Installation 2. Install air bag assembly fixing nuts and tighten to

specified torque.
3. Connect air bag assembly harness connector.
4. Install instrument panel lower center cover.
5. Install meter cluster assembly and connect harness
connector.
6. Install lower cluster with ashtray.
7. Install instrument panel door side lower cover.
8. Connect engine hood opener lever.
9. Install instrument panel assist side lower cover.
10. Install glove box cover.
11. Install glove box assembly with lid.
12. Install ECM and SDM cover.
13. Install rear console assembly and connect harness
connector.
15. Install gear control knob.
827RS001
1. Install passenger air bag assembly. 16. Enable the SRS (Refer to “Enabling the SRS” in this
section).

Fastener Tightening Specification
Application N·m Lb Ft Lb In.
SDM 10 — 87
Driver air bag fixing bolt 8.8 — 78
Steering wheel fixing bolt 34 25 —
Steering column (dash panel side fixing bolts) 20 14 —
Steering column (Pedal bracket fixing bolt) 20 14 —
Steering column (Universal joint fixing bolt) 31 23 —
Passenger Air Bag fixing nuts 6 — 52
RESTRAINT CONTROL SYSTEM 9J1–1
Trooper
RESTRAINTS
RESTRAINT CONTROL SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 9J1–1 DTC 19 Passenger Deployment Loop
Diagnostic Information . . . . . . . . . . . . . . . . . . . 9J1–2 Short To Voltage . . . . . . . . . . . . . . . . . . . . . . . . 9J1–21
System Schematic . . . . . . . . . . . . . . . . . . . . . . 9J1–4 DTC 21 Driver Deployment Loop
SRS Diagnostic System Check . . . . . . . . . . . . 9J1–4 Resistance High . . . . . . . . . . . . . . . . . . . . . . . . 9J1–23
Chart A SDM Integrity Check . . . . . . . . . . . . . 9J1–6 DTC 22 Driver Deployment Loop
Chart B “AIR BAG” Warning Lamp Resistance Low . . . . . . . . . . . . . . . . . . . . . . . . 9J1–26
Comes “ON” Steady . . . . . . . . . . . . . . . . . . . . 9J1–8 DTC 24 Driver Deployment Loop
Chart C “AIR BAG” Warning Lamp Does Short To Ground . . . . . . . . . . . . . . . . . . . . . . . . 9J1–28
Not Come “ON” Steady (1/2) . . . . . . . . . . . . . 9J1–10 DTC 25 Driver Deployment Loop
DTC 15 Passenger Deployment Loop Short To Voltage . . . . . . . . . . . . . . . . . . . . . . . . 9J1–30
Resistance High . . . . . . . . . . . . . . . . . . . . . . . . 9J1–13 DTC 26 Driver Deployment Loop Open . . . . 9J1–32
DTC 16 Passenger Deployment loop DTC 51 Deployment Event Commanded . . . 9J1–34
Resistance Low . . . . . . . . . . . . . . . . . . . . . . . . 9J1–15 DTC 53 Deployment Commanded With
DTC 17 Passenger Deployment Loop Deployment Loop Fault Or Energy
Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J1–17 Reserves Out Of Range . . . . . . . . . . . . . . . . . 9J1–36
DTC 18 Passenger Deployment Loop DTC 61 Warning Lamp Circuit Failure . . . . . 9J1–38
Short To Ground . . . . . . . . . . . . . . . . . . . . . . . . 9J1–19 DTC 71 Internal SDM Fault . . . . . . . . . . . . . . 9J1–40
Service Precaution
systems.
9J1–2 RESTRAINT CONTROL SYSTEM
Diagnostic Information detected since the SRS codes were last cleared during
service.
CAUTION: When fasteners are removed, always 1. Active Codes — Faults that are presently detected
reinstall them at the same location from which they this ignition cycle. Active codes are stored in RAM
were removed. if a fastener needs to be replaced, use (Random Access Memory).
the correct part number fastener for that application. 2. History Codes — All faults detected since the last
if the correct part number fastener is not available, a time the history fault memory was cleared. History
fastener of equal size and strength (or stronger) may codes are stored in EEPROM. (Electronically
be used. fasteners that are not reused, and those Erasable Programmable Read only Memory)
requiring thread locking compound will be called
out. the correct torque value must be used when How To Read Trouble Codes
installing fasteners that require it. if the above
conditions are not followed, parts or system damage All codes (Active and history) can be read (or cleared) by
could result. using a scan tool or equivalent.
If a PDT is not available, have the vehicle serviced by
Diagnostic Procedures ISUZU dealer.
WARNING: TO AVOID DEPLOYMENT WHEN
TROUBLESHOOTING THE SRS, DO NOT USE How To Clear Trouble Codes
ELECTRICAL TEST EQUIPMENT SUCH AS A Trouble codes can only be cleared by using a Scan Tool.
BATTERY–POWERED OR AC–POWERED If a “scan tool” is not available then inform the owner of the
VOLTMETER, OHMMETER, ETC., OR ANY TYPE OF stored codes and suggest that the codes are cleared
ELECTRICAL EQUIPMENT OTHER THAN THAT upon the next visit to an Isuzu dealership.
SPECIFIED IN THIS MANUAL. DO NOT USE A NON
POWERED, PROBE–TYPE TESTER. Scan Tool Diagnostics
INSTRUCTIONS IN THIS MANUAL MUST BE A scan tool can be used to read current and history codes
FOLLOWED CAREFULLY, OTHERWISE PERSONAL and to clear all history codes after a repair is complete.
INJURY MAY RESULT. The scan tool must be updated to communicate with the
The diagnostic procedures used in this section are SRS through a replaceable cartridge or a manufacturer’s
designed to aid in finding and repairing SRS problems. update before it can be used for SRS diagnostics. To use
Outlined below are the steps to find and repair SRS the scan tool, connect it to the DLC connector and turn the
problems quickly and effectively. Failure to carefully ignition switch “ON”. Then follow the manufacturer’s
follow these procedures may result in extended directions for communication with the SRS. The scan tool
diagnostic time, incorrect diagnosis and incorrect parts reads serial data from the SDM “Serial Data” output
replacement. (terminal 24) to the DLC connector (terminal 9).
1. Perform The “SRS Diagnostic System Check”.
The “SRS Diagnostic System Check” should always Basic Knowledge Required
be the starting point of any SRS diagnostics. The Before using this section of the Service Manual, there is
“SRS Diagnostic System Check” checks for proper some basic knowledge which will be required. Without
“AIR BAG” warning lamp operation and checks for this knowledge, you will have trouble using the diagnostic
SRS trouble codes using both “Flash Code” and procedures in this section. Use care to prevent harm or
“Scan Tool” Methods. unwanted deployment. Read all cautions in the service
2. Refer To The Proper Diagnostic Chart As Directed manual and on warning labels attached to SRS
By The “SRS Diagnostic System Check”. components.
The “SRS Diagnostic System Check” will lead you to
the correct chart to diagnose any SRS problems. Basic Electrical Circuits
Bypassing these procedures may result in extended You should understand the basic theory of electricity
diagnostic time, incorrect diagnosis and incorrect including series and parallel circuits, and understand the
parts replacement. voltage drops across series resistors. You should know
3. Repeat The “SRS Diagnostic System Check” the meaning of voltage (volts), current (amps), and
After Any Repair Or Diagnostic Procedures Have resistance (ohms). You should understand what happens
Been Performed. in a circuit with an open or a shorted wire. You should be
Preforming the “SRS Diagnostic System Check” after able to read and understand a wiring diagram.
all repair or diagnostic procedures will assure that the
repair has been made correctly and that no other “Flash Code” Diagnostics
conditions exist. Flash code diagnostics can be used to read active codes
and to determine if history codes are present but cannot
Diagnostic Codes be used to clear codes or read history codes. Flash code
The Sensing and Diagnostic Module (SDM) maintains a diagnostics is enabled by grounding by terminal 4
history record of all diagnostic codes that have been shorting to terminal 13 of the DLC connector with the
ignition switch “ON”. Grounding terminal 4 of the DLC
connector pulls the “Diagnostics Request” input (Terminal
1) of the SDM low and signals the SDM to enter the flash
code diagnostic display mode.
The SDM displays the trouble codes by flashing the
warning lamp. Each code that is displayed will consist of a
number of flashes which represents the tens digit, a 1.2
second pause, following by a number of flashes which
represents the ones digit of the code. Each code is
displayed one time before moving on to the next code.
After all of the codes have been displayed, the entire code
sequence will continually by repeated until ground is
removed from terminal 4 of the DLC connector.
Two special codes exist when reading in the flash code
mode (Flash Code 12 and Flash Code 13). “Flash Code
12“ will always be the first code displayed when the flash
code mode is enable Code 12 is not an indication of a SRS
problem but an indication that the flash code mode has
been enabled. If there are no active or history codes
present, the SDM will display code 12 until ground is
removed from the DLC connector at terminal 4. “flash
Code 13” will be displayed if history codes are present. To
read the history codes a scan tool must be used.
System Schematic
D09RW001
SRS Diagnostic System Check Circuit Description

The diagnostic procedures used in this section are When the ignition switch is first turned “ON”, “Ignition 1”
designed to find and repair SRS malfunctions. To get the voltage is applied from the “C–21” fuse to the SDM at the
best results, it is important to use the diagnostic charts “Ignition 1” input terminals “12”. The SDM responds by
and follow the sequence listed below: flashing the “AIR BAG” warning lamp seven times, while
A. Perform the “SRS Diagnostic System Check.” performing tests on the SRS.
The “SRS Diagnostic System Check” must be the
starting point of any SRS diagnostics. The “SRS Notes On System Check Chart:
Diagnostic System Check” checks for proper “AIR 1. The “AIR BAG” warning lamp should flash seven
BAG” warning lamp operation, the ability of the SDM times after ignition is first turned “ON”.
to communicate through the “Serial Data” line and 2. After the “AIR BAG” warning lamp flashes seven
whether SRS diagnostic trouble codes exist. times, it should turn “OFF”
B. Refer to the proper diagnostic chart as directed by the 3. This test checks for the proper operation of the
“SRS Diagnostic System Check.” “Serial Data” line. This test will also determine
The “SRS Diagnostic System Check” will lead you to whether history diagnostic trouble codes are stored
the correct chart to diagnose any SRS malfunctions. and, if so, identify them.
Bypassing these procedures may result in extended 4. Improper operation of the “AIR BAG” warning lamp
diagnostic time, incorrect diagnosis and incorrect is indicated. This test differentiates a warning lamp
parts replacement. stays “ON” condition from a warning lamp does not
C. Repeat the “SRS Diagnostic System Check” after any come “ON” condition.
repair or diagnostic procedures have been 5. This test checks for proper operation of the “Serial
preformed. Data” line. This test will also identify the stored
Performing the “SRS Diagnostic System Check” after diagnostic trouble codes and whether they are
all repair or diagnostic procedures will ensure that the current or history.
repair has been made correctly and that no other
malfunctions exist Diagnostic Aids:
The order in which diagnostic trouble codes are
diagnosed is very important. Failure to diagnose the
diagnostic trouble codes in the order specified may result in extended diagnostic time, incorrect diagnosis and
incorrect parts replacement.
SRS Diagnostic System Check

Step Action Yes No
1 Note the “Air Bag” warning lamp as ignition switch is turned “ON.”
Does the “AIR BAG” warning lamp flash seven (7) times? Go to Step 2 Go to Step 3
2 Note the “AIR BAG” warning lamp after it flashed 7 times.
Does the “AIR BAG” warning lamp go “OFF”? Go to Step 4 Go to Step 5
3 Note the “AIR BAG” warning lamp as ignition switch is turned
“ON”.
Does the “AIR BAG” warning lamp come “ON” steady? Go to Chart B Go to Chart C
4 1. Note the “AIR BAG” warning lamp as that ignition switch is Ignition switch
turned “ON.” “OFF”
Ignition switch “OFF.” When DTC 71 is
2. Connect a scan tool to data link connector. set, go to DTC 71
3. Follow direction given in the scan tool instruction manual. Chart SRS is functional
Ignition switch “ON.” For all other and free of
history codes malfuncitons, no
4. Request the SRS diagnostic trouble code display, recode all
refer to further diagnosis
history diagnostic trouble code(s). specify as such, on repair
“Diagnostic Aids” is required
order
For that specific If scan tool
Is (are) diagnostic trouble code(s) displayed? DTC indicated “NO
A history DTC DATA
indicates the RECEIVED,”
malfunction has refer to chassis
been repaired or electrical
is intermittent section8
5 1. Ignition switch “OFF.” Ignition switch
2. Connect a scan tool to data link connector. “OFF”
3. Follow directions as given in the scan tool instruction manual. When DTC 53 is
4. Ignition switch “ON.” set, go to DTC 53
5. Request the SRS diagnostic trouble code display, Recode all chart
diagnostic trouble code(s), specifying as current or history on When DTC 51 is
repair order. set, go to DTC 51
chart
Is (are) diagnostic trouble code (s) displayed?
When DTC 19 is
set, go to DTC 19
chart
When DTC 25 is
set, go to DTC 25
chart
Diagnose
remaining current
DTCs from
lowest to highest.
When only history
DTCs exist, refer
to “Diagnostics
Aids” for that
specific DTC If scan tool
A history DTC indicates “No
indicates the Data Received,”
malfunction has refer to chassis
been repaired or electrical
is intermittent section8
Chart A SDM Integrity Check
D09RW001
Circuit Description: Chart Test Description:

When the SDM recognizes “Ignition 1” voltage, applied to Number(s) below refer to step number(s) on the
terminals “12”, is greater than 9 volts, the “AIR BAG” diagnostic chart:
warning lamp is flashed 7 times to verify operation. At this 1. This test confirms a current malfunction. If no
time the SDM performs “Turn–ON” tests followed by current malfunction is occurring (history DTC set)
“Continuous Monitoring” tests. When a malfunction is the “Diagnostic Aids” for the appropriate diagnostic
detected, the SDM sets a current diagnostic trouble code trouble code should be referenced. The SDM
and illuminates the “AIR BAG” warning lamp. The SDM should not be replaced for a history diagnostic
will clear current diagnostic trouble codes and move them trouble code.
to a history file when the malfunction is no longer detected 2. This test checks for a malfunction introduced into the
and/or the ignition switch is cycled, except for DTCs 19, SRS during the diagnostic process. It is extremely
25, 51, 53 and 71. DTC 71 can only be cleared using a unlikely that a malfunctioning SDM would cause a
scan tool “Clear Codes” command. If DTCs 51, 53 are not new malfunction to occur during the diagnostic
indicated then DTC 71 is not existing. DTCs 51, 53 and 71 process.
can not be cleared after a “Clear Codes” command is 3. When all circuitry outside the SDM has been found
issued. to operate properly, as indicated by the appropriate
diagnostic chart, then and only then should the SDM
be replaced.
Chart A SDM Integrity Check

WARNING: DURING SERVICE PROCEDURES. BE VERY CAREFUL WHEN HANDLING A SENSING AND
DIAGNOSTIC MODULE (SDM). NEVER STRIKE OR JAR THE SDM. NEVER POWER UP THE SRS WHEN THE
SDM IS NOT RIGIDLY ATTACHED TO THE VEHICLE. ALL SDM AND MOUNTING BRACKET FASTENERS MUST
BE CAREFULLY TORQUED AND THE ARROW MUST BE POINTING TOWARD THE FRONT OF THE VEHICLE
TO ENSURE PROPER OPERATION OF THE SRS. THE SDM COULD BE ACTIVATED WHEN POWERED WHILE
NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH COULD CAUSE DEPLOYMENT AND RESULT IN
PERSONAL INJURY.
Step Action Yes No

1 1. This chart assumes that the “SRS Diagnostic System Check”
and either a symptom chart or a diagnostic trouble code chart
diagnosis have been performed. When all circuitry outside the
SDM has been found to operate properly, as indicated by the
appropriate diagnostic chart, and the symptom or DTC
remains current, the following
2. Diagnostic procedures must be performed to verify the need
for SDM replacement.
The symptom or
3. Ignition switch “OFF”.
DTC is no longer
4. Reconnect all SRS components, ensure all components are
occurring
properly mounted.
Clear SRS
5. Ensure the ignition switch has been “OFF” for at least 15
diagnostic trouble
seconds.
codes
6. Note “AIR BAG” warning lamp as ignition switch is turned
Repeat “SRS
“ON.”
Diagnostic
Does warning lamp flash 7 times then go “OFF”? System Check” Go to Step 2
2 Using a scan tool request diagnostic trouble code display. Ignition switch
“OFF”
Is the same symptom or DTC occurring as was when the “SRS
Go to the
Diagnostic System Check ” was first performed?
appropriate chart
for the indicated
Go to Step 3 malfunction
3 1. Clear “SRS Diagnostic Trouble Codes”. SRS is functional
2. Ignition switch “OFF” for at least two minutes. and free of
3. Note “AIR BAG” warning lamp as ignition switch is turned malfunctions
“ON.” No further Ignition switch
diagnosis is “OFF”
Does warning lamp flash 7 times then go “OFF”?
required Replace SDM
4 Reconnect all SRS components, ensure all components are
Repeat the “SRS
properly mounted.
Diagnostic
Was this step finished? System Check” Go to Step 4
Chart B “AIR BAG” Warning Lamp Comes “ON” Steady
D09RW001
Circuit Description:
When the ignition switch is first turned “ON”, “Ignition 1”
voltage is applied from the “C–10” fuse to “AIR BAG”,
warning lamp which is connected to “SRS Warning
Lamp”, terminal “7”. The “C–21” fuses apply system
voltage to the “Ignition 1” inputs, terminals “12”. The SDM
responds by flashing the “AIR BAG” warning lamp 7
times. If “Ignition 1” is less than 9 volts, the “AIR BAG”
warning lamp will come “ON” solid with no DTCs set.
Chart Test Description:

Number(s) below refer to step number(s) on the
diagnostic chart.
2. This test checks for an open in the “Ignition 1” circuit
to the SDM.
3. This test checks for the voltage of “IGNITION 1”.
4. This test determines whether the malfunction is a
short to ground in CKT IB04–WHT/RED.
Chart B “AIR BAG” warning lamp comes “ON” Steady

Step Action Yes No
1 1. When measurements are requested in this chart use J–39200
DVM with correct terminal adapter from J–35616–A.
2. Ignition switch “OFF.”
3. Connect scan tool to data link connector, follow directions as
given in the scan tool instruction MANUAL.
4. Ignition switch “ON.”
5. Request SRS diagnostic trouble code display.
Dose scan tool indicate “No Data Received”? Go to Step 2 Go to Step 3
2 1. Ignition switch “OFF”. Connect SDM
2. Inspect SDM harness connector connection to SDM. securely to
de–activate
Is it securely connected to the SDM?
Ignition switch shorting clip in
“OFF” SDM harness
Replace SDM connector
3 Using scan tool, request SRS data list. Ignition switch
“OFF”
Is “ignition” more than 9 volts?
Replace SDM
4 1. Ignition switch “OFF.”
2. Disconnect SRS coil and passenger air bag assemblies.
yellow 2–pin connector located at base of steering column and
behind the glove box assembly.
Disconnect SDM.
3. Disconnect the connector of “SRS Warning Lamp” of
instrument cluster.
4. Measure resistance from SDM harness connector terminal “6”
Replace SRS
to ground.
harness
Does J–39200 display “OL” (Infinite)? Go to Chart A Go to Step 5
Repeat the “SRS
properly mounted.
Diagnostic
Chart C “AIR BAG” Warning Lamp Does Not Come “ON” Steady (1/2)
D09RW001
Circuit Description: 2. This test determines whether the voltage is present

When the ignition switch is first turned “ON”, “Ignition 1” in the warning lamp circuit.
voltage is applied from the “C–10” fuse to the “AIR BAG” 3. This test determines if the malfunction is in the
warning lamp which is connected to “SRS Warning instrument cluster.
Lamp”, terminal “7”. The “C–21” fuse apply system 4. This test checks for open in the warning lamp
voltage to the “Ignition 1” inputs, terminals “12”. The SDM circuitry.
responds by flashing the “AIR BAG” warning lamp seven 5. This test isolates the IB04–WHT/RED circuit and
times. If “Ignition 1” is more than 16 volts, the “AIR BAG” checks for a short in the IB04–WHT/RED circuit to
warning lamp will be still “OFF” solid with no DTCs set. B+.
8. This test checks for a short from the SDM warning lamp
Chart Test description: power feed circuit to ground.
Number(s) below refer to step number(s) on the 9. This test determines whether the short to ground is due
diagnostic chart: to a short in the wiring.
1. This test decides whether power is available to SDM
warning lamp power feed circuit.
Chart C “AIR BAG” Warning Lamp Does Not Come “ON” Steady
Step Action Yes No
1 1. When measurements are requested in this chart,use J–39200
3. Remove and inspect “C–10” fuse to the “AIR BAG” warning
lamp.
Is fuse good? Go to Step 2 Go to Step 7
2. Disconnect SRS coil and passenger air bag assemblies.
Yellow 2–pin connector located at base of steering column and
3. Disconnect SDM.
5. Measure voltage on SDM harness connector from terminal “7”
to terminal “6” (ground).
Is system voltage present on terminal “7”? Go to Step 4 Go to Step 3
2. Remove instrument meter cluster.
3. Check for proper connection to instrument cluster at
IB04–WHT/RED terminal.
4. If ok, then remove and inspect “AIR BAG” bulb.
Replace bulb
Is bulb good? Go to Step 5 Go to Step 6
2. Disconnect instrument meter cluster harness connector.
4. Measure voltage on SDM harness connector from terminal “7”
Replace SRS
to terminal “6” (GROUND).
harness
Is voltage 1 volt or less? Go to Chart A Go to Step 6
5 1. Install bulb. Service
2. Measure resistance from instrument meter cluster harness instrument meter
connector IB04–WHT/RED terminal to SDM harness cluster
connector terminal “7”. Install instrument Replace SRS
meter cluster harness
Is resistance 5.0 ohms or less?
Repeat the “SRS
properly mounted.
Diagnostic
7 Perform chart C.
Was this step finished? Go to Step 8 Go to Step 1
8 1. Replace “C–10” fuse.
2. Ignition switch “ON” wait 10 Seconds then ignition switch “Off.”
Install “C–10”
3. Remove and inspect “C–10” fuse.
fuse
Is fuse good? Go to Step 10 Go to Step 9
Chart C “AIR BAG” Warning Lamp Does Not Come “ON” Steady (Cont’d)
Step Action Yes No
9 1. Disconnect SRS coil and passenger air bag assemblies.
Yellow 2–pin connector located at base of steering column and
2. Disconnect SDM.
3. Replace “C–10” fuse.
Replace SRS
4. Ignition switch “ON” wait 10 seconds.
harness
5. Ignition switch “OFF”.
Install“C–10” Replace “C–10”
6. Remove and inspection “C–10” fuse.
fuse fuse
Is fuse good? Go to Chart A Go to Step 10
Repeat the “SRS
properly mounted.
Diagnostic
DTC 15 Passenger Deployment Loop Resistance High
D09RW001
Circuit Description: Action Taken:

When the ignition switch is turned “ON”, the SDM will SDM turns “ON” the “AIR BAG” warning lamp and sets a
perform tests to diagnose critical malfunctions within diagnostic trouble code.
itself. Upon passing these tests “Ignition 1”, and
deployment loop voltages are measured to ensure they DTC Will Clear When:
are within their respective normal voltage ranges. The The ignition switch is turned “OFF.”
SDM then proceeds with the “Resistance Measurement
Test”. “Passenger Bag Low” terminal “16” is grounded DTC Chart Test Description:
through a resister and the passenger current source Number(s) below refer to step number(s) on the
connected to “Passenger Bag High” terminal “15” allows a diagnostic chart:
known amount of current to flow. By monitoring the 2. This test determines whether the malfunction is in
voltage difference between “Passenger Bag High” and the SDM.
“Passenger Bag Low” the SDM calculates the combined
3. This test verifies proper connection of the yellow
resistance of the passenger air bag assembly, harness
2–pin connector.
wiring CKTs IB07–YEL/GRN and IB08–YEL/RED
connector terminal contact. 4. This test checks for proper contact and/or corrosion
of the yellow 2–pin connector terminals.
DTC Will Set When: 5. The test checks for a malfunctioning passenger air
The combined resistance of the passenger air bag bag assembly.
assembly, harness wiring CKTs IB07–YEL/GRN and 6. This test determines whether the malfunction is due
IB08–YEL/RED, and connector terminal contact is above to high resistance in the wiring.
a specified value. This test is run once each ignition cycle
during the “Resistance Measurement Test” when: Diagnostic Aids:
1. No “higher priority faults” are detected during An intermittent condition is likely to be caused by a poor
“Turn–ON”, connection at the passenger air bag assembly harness
2. “Ignition 1” voltage is in the specified value. connector terminals “1” and “2”, SDM terminal “15” and
“16”, or a poor wire to terminal connection in CKTs
IB07–YEL/GRN and IB08–YEL/RED. This test for this
diagnostic trouble code is only run while the “AIR BAG”
warning lamp is performing the bulb check, unless DTC present, the DTC will not reappear until the next ignition
17 or DTC 26 is detected. When a scan tool “Clear cycle.
Codes” command is issued and the malfunction is still
DTC 15 Passenger Deployment loop Resistance High

Step Action Yes No
1 Was the “SRS Diagnostic System Check” Performed? Go to The “SRS
Diagnostic
Go to Step 2 System Check”
2. Use scan tool data list function, read and record the passenger
deployment loop resistance.
Is passenger resist. more than 2.9 ohms? Go to Step 3 Go to Chart A
3 1. Ignition switch “Off.” Seat passenger
2. Make sure the passenger air bag assembly yellow 2–pin Air Bag assembly
connector located behind the glove box assembly is seated yellow 2–pin
properly. connector
properly
Is the yellow 2–pin connector connected properly?
4 1. Disconnect and inspect the passenger air bag assembly
yellow 2–pin connector located behind the glove box
assembly.
2. If ok, reconnect the passenger air bag assembly 2–pin
connector.
Is DTC 15 current? Go to Step 5 Go to Step 7
5 1. Ignition switch “Off.”
2. Disconnect SRS coil and passenger air bag assembly, yellow
2–pin connector located at the base of the steering column and
Ignition switch
3. Connect J–41433 SRS driver / passenger load tool and
“Off”
appropriate adapters to SRS coil and passenger air bag
Replace the
assembly harness connectors.
passenger air
bag assembly
Is DTC 15 Current? Go to Step 6 Go to Step 7
2. There has been an increase in the total circuit resistance of the
passenger inflator deployment loop.
3. Use the high resolution ohmmeter mode of the DVM while
checking CKTS IB07–YEL/GRN and IB08–YEL/RED, and
Replace SRS
SDM connector terminal “15” and “16” to locate the root cause.
harness
Was a fault found? Go to Step 7 Go to Chart A
7 1. Reconnect all components ensure all component are properly
mounted.
Repeat the “SRS
2. Clear diagnostic trouble codes.
Diagnostic
Was This step finished? System Check” Go to Chart 7
DTC 16 Passenger Deployment loop Resistance Low
D09RW001

When the ignition switch is turned “ON”, the SDM will SDM turns “ON” the “AIR BAG” warning lamp and sets a
perform tests to diagnose critical malfunctions within diagnostic trouble code.
are within their respective normal voltage ranges. The The ignition switch is turned “OFF.”
SDM then proceeds with the “Resistance Measurement
Test”. “Passenger Bag Low” terminal “16” is grounded DTC Chart Test Description:
through a resistor and the passenger current source Number(s) below refer to step number(s) on the
connected to “Passenger Bag High” terminal “15” allows a diagnostic chart:
known amount of current to flow. By monitoring the 2. This test determines whether the malfunction is in
voltage difference between “Passenger Bag High” and the SDM.
“Passenger Bag Low”, the SDM calculates the combined
3. This test verifies connection of the yellow 2–pin
resistance of the passenger air bag assembly, harness
connector.
wiring CKTs IB07–YEL/GRN and IB08–YEL/RED
connector terminal contact. 4. This test cheeks for proper operation of the shorting
clip in the yellow 2–pin connector.
DTC Will Set When: 5. The test checks for a malfunction passenger air bag
The combined resistance of the passenger air bag assembly.
assembly, harness wiring CKTs IB07–YEL/GRN and 6. This test determines whether the malfunctioning is
IB08–YEL/RED, and connector terminal contact is above due to shortening in the wiring.
a specified value. This test is run once each ignition cycle
during the “Resistance Measurement Test” when: Diagnostic Aids:
1. No “higher priority faults” are detected during An intermittent condition is likely to be caused by a short
“Turn–ON”, between CKTs IB07–YEL/GRN and IB08–YEL/RED, or a
2. “Ignition 1” voltage is in the specified value. malfunctioning shorting clip on the passenger air bag
assembly which would require replacement of the air bag
assembly. The test for this diagnostic trouble code is only
run while “AIR BAG” warning lamp is performing the bulb
check, unless DTC 17 or DTC 26 is detected. When a malfunction is still present, the DTC will not reappear until
scan tool “Clear Codes” command is issued and the the next ignition cycle.
DTC 16 Passenger Deployment loop Resistance Low

Step Action Yes No
1 Was the “SRS Diagnostic System Check” performed? Repeat the “SRS
Diagnostic
2. Using scan tool data list function, read and record the
passenger deployment loop resistance.
Is passenger resist. less than 1.4 ohms? Go to Step 3 Go to Chart A
3 1. Ignition switch “Off.” Seat passenger
2. Make sure the passenger air bag assembly yellow 2–pin air bag assembly
properly. connector
properly
assembly.
connector.
Is DTC 16 Current? Go to Step 5 Go to Step 7
Ignition switch
3. Connect J–41433 SRS driver/passenger load tool and
“Off”
Replace the
passenger air
bag assembly
2. There has been a decrease in the total circuit resistance of the
passenger inflator deployment loop.
Replace SRS
harness
7 1. Reconnect all components, ensure all component are properly
mounted.
Repeat the “SRS
Diagnostic
DTC 17 Passenger Deployment Loop Open
D09RW001
Circuit Description: below a specified value for 500 milliseconds during

When the ignition switch is turned “ON”, the SDM will “Continuous Monitoring”.
perform tests to diagnose critical malfunctions within
itself. Upon passing these tests, “Ignition 1”, and
DTC Chart Test Description:
deployment loop voltages are measured to ensure they Number(s) below refer to step number(s) on the
are within their respective normal voltage ranges. During diagnostic chart:
“Continuous Monitoring” diagnostics, a fixed amount of 2. This test determines whether the malfunction is in
current is flowing in the deployment loop. This produces the SDM.
proportional voltage drops in the loop. By monitoring the 3. This test verifies proper connection of the yellow
voltage difference between “Passenger Bag High” and 2–pin connector.
“Passenger Bag Low”, the SDM calculates the combined 4. This test cheeks for proper contact and/or corrosion
resistance of the passenger air bag assembly, harness of the shorting clip in the yellow 2–pin connector
wiring CKTs IB07–YEL/GRN AND IB08–YEL/RED, and terminals.
connector terminal contact. 5. The test checks for a malfunctioning passenger air
bag assembly.
DTC Will Set When:
6. This test determines whether the open in the wiring.
The voltage difference between “Passenger Bag High”
terminal “15” and “Passenger Bag Low” terminal “16” is Diagnostic Aids:
above or equal to a specified value for 500 milliseconds
An intermittent condition is likely to be caused by a poor
during “Continuous Monitoring”.
connection at the passenger air bag assembly harness
Action Taken: connector terminals“1” and “2”, SDM terminals “15” and
“16”, or an open in CKT IB07–YEL/GRN and
SDM turns “ON” the “AIR BAG” warning lamp and sets a IB08–YEL/RED.
diagnostic trouble code.
DTC Will Clear When:

The voltage difference between “Passenger Bag High”
terminal “15” and “Passenger Bag Low” terminal “16” is
DTC 17 Passenger Deployment Loop Open

Step Action Yes No
1 Was the “SRS Diagnostic System Check” performed? Go to the “SRS
Diagnostic
2. Using scan tool data list function, read and record the
passenger differential voltage.
Is passenger VDIF. 0.4 volts or more? Go to Step 3 Go to Chart A
3 1. Ignition switch “OFF”. Seat passenger
2. Make sure the passenger air bag assembly yellow 2–pin air bag assembly
properly. connector
properly
assembly.
connector.
3. Ignition switch “ON”.
Ignition switch
3. Connect J–41433 SRS driver / passenger load tool and
“Off”
Replace the
passenger air
bag assembly
2. There has been an open circuit resistance in the passenger
deployment loop.
Replace SRS
harness
mounted.
Go to the “SRS
Diagnostic
DTC 18 Passenger Deployment Loop Short To Ground
D09RW001
Circuit Description: DTC Chart Test Description:

When the ignition switch is turned “ON”, the SDM will Number(s) below refer to circled number(s) on the
perform tests to diagnose critical malfunctions within diagnostic chart.
itself. Upon passing these tests, “Ignition 1”, and 2. This test determines whether the SDM is
deployment loop voltages are measured to ensure they malfunctioning.
are within their respective normal voltage ranges. 3. This test isolates the malfunction to one side of the
The SDM monitors the voltages at “Driver Bag Low” passenger air bag assembly yellow 2–pin connector
terminal “4” and “Passenger Bag Low” terminal “16” to behind glove box compartment.
detect short to ground in the air bag assembly circuits. 4. This test determines whether the malfunction is in
CKT IB07–YEL/GRN.
DTC Will Set When:
5. This test determines whether the malfunction is in
Neither of the two air bag assemblies is open. CKT IB08–YEL/RED.
“Ignition 1” is within the normal operating voltage range.
Once these conditions are met and the voltage at Diagnostic Aids:
“Passenger Bag Low” is below a specified value, DTC 18
will set. This test is run once each ignition cycle and An intermittent condition is likely to be caused by a short
“Continuous Monitoring”. to ground in the passenger air bag assembly circuit.
Inspect CKTs IB07–YEL/GRN and IB08–YEL/RED
Action Taken: carefully for cutting or chafing. If the wiring pigtail of the
passenger air bag assembly is damaged, the component
SDM turns “ON” the “AIR BAG” warning lamp and sets a
must be replaced.

This malfunction is no longer occurring and the ignition
switch is turned “OFF”.
DTC 18 Passenger Deployment Loop Short To Ground

Step Action Yes No
Diagnostic
3. Connect scan tool data link connector. follow directions as
given in the scan tool operator’s MANUAL.
5. Read passenger sense LO.
Is passenger sense LO less than 1.5 volts? Go to Step 3 Go to Chart A
2. Disconnect passenger air bag assembly yellow 2–pin
connector behind the glove box assembly.
3. Leave driver air bag assembly connected.
Ignition switch
4. Connect SRS driver / passenger load tool J–41433 and
“OFF”
appropriate adapter to passenger air bag assembly harness
Replace
connector.
passenger air
bag assembly
4 1. Ignition switch “OFF”.
2. Disconnect SRS driver / passenger load tool
3. Measure resistance on SDM harness connector from terminal Replace SRS
“15” to terminal “16” (ground). Harness
Does J–39200 display “OL” (Infinite)? Go to Step 5 Go to Step 6
5 Measure resistance on SDM harness connector from terminal
Replace SRS
“16” to terminal “6” (ground).
Harness
Does J–39200 display “OL” (Infinite)? Go to Chart A Go to Step 6
6 1. Reconnect all components and ensure all component are
Properly Mounted.
Go to the “SRS
Diagnostic
Was this step finished? system check” Go to Step 6
DTC 19 Passenger Deployment Loop Short To Voltage
D09RW001

When the ignition switch is turned “ON”, the SDM will Number(s) below refer to step number(s) on the
perform tests to diagnose critical malfunctions within diagnostic chart:
itself. Upon passing these tests, “Ignition 1”, and 2. This test determines whether the malfunction is in
deployment loop voltages are measured to ensure they the SDM.
The SDM monitors the voltages at “Driver Bag Low” passenger air bag assembly yellow 2–pin connector
terminal “4” and “Passenger Bag Low” terminal “16” to behind glove box assembly.
detect short to B+ in the air bag assembly circuits. 4. This test determines whether the malfunction is in
CKT IB07–YEL/GRN.
DTC Will Set When:
“Ignition 1” is within the normal operating voltage range. CKT IB08–YEL/RED.
Once these conditions are met and the voltage at
“Passenger Bag Low” is above a specified value, DTC 19 Diagnostic Aids:
will set. This test is run once each ignition cycle and
“Continuous Monitoring”. An intermittent condition is likely to be caused by a short
to B+ in the passenger air bag assembly circuit. Inspect
Action Taken: CKTs IB07–YEL/GRN and IB08–YEL/RED carefully for
cutting or chafing. If the wiring pigtail of the passenger air
SDM turns “ON” the “AIR BAG” warning lamp and sets
bag assembly is damaged, the component must be
DTC 19 and also DTC 71.
replaced. A careful inspection of CKT IB07–YEL/GRN
DTC Will Clear When: and IB08–YEL/RED, including the passenger air bag
assembly pigtail is essential to ensure that the
The SDM is replaced. replacement SDM will not be damaged.
DTC 19 Passenger Deployment Loop Short To Voltage

CAUTION: When DTC 19 has been set, it is necessary to replace the SDM. Setting DTC 19 will also cause DTC
71 to set. When a scan tool “CLEAR CODES” command is issued and the malfunction is no longer present,
DTC 71 will remain current. Ensure that the short to voltage condition is repaired prior to installing a
replacement SDM to avoid damaging the SDM.
Step Action Yes No

1 Perform the “SRS Diagnostic System Check.” Repeat the “SRS
Diagnostic
Was the “SRS Diagnostic System Check” performed?
DVM With correct terminal adapter from J–35616–A.
given in the scan tool operator’s manual.
5. Read passenger sense LO.
Is passenger sense LO more than 3.5 volts? Go to Step 3 Go to chart A
2. Disconnect passenger air bag assembly yellow 2–pin
connector behind the glove box assembly.
3. Leave driver air bag assembly connected.
Ignition switch
“OFF”
appropriate adapter to passenger air bag assembly harness
Replace
connector.
passenger air
bag assembly
Is passenger sense LO more than 3.5 volts? Go to Step 4 Go to Step 6
2. Disconnect SDM.
3. Disconnect SRS driver / passenger load tool.
4. Measure resistance on SDM harness connector from terminal
Replace SRS
“15” to terminal “12” (ignition).
harness
Does J–39200 display “OL” (infinite)? Go to Step 5 Go to Step
5 Measure resistance on SDM harness connector from terminal
replace SRS
“16” and terminal “12” (ignition).
harness
Does J–39200 display “OL” (infinite)? Go to Chart A Go to Step 6
Ignition switch
mounted.
“OFF”
2. Ignition switch “ON”.
Replace SDM
Is passenger senslo less than 3.5 volts? Go to Step 7 Go to Chart A
mounted.
Repeat the “SRS
Diagnostic
DTC 21 Driver Deployment Loop Resistance High
D09RW001

When the ignition switch is turned “ON”, the SDM will SDM turns “ON” the “AIR BAG” warning lamp and sets
perform tests to diagnose critical malfunctions within DTC 21.
are within their respective normal voltage ranges. The ignition switch is turned “OFF”.
The SDM then proceeds with the “Resistance
Measurement Test” “Driver Bag Low” terminal “4” is DTC Chart Test Description:
grounded through a current sink and the driver current Number(s) below refer to step number(s) on the
source connected to “Driver Bag High” terminal “3” allows diagnostic chart:
a known amount of current to flow. By monitoring the 2. This test determines whether the malfunction is in
voltage difference between “Driver Bag High” and “Driver the SDM.
Bag Low”, the SDM calculates the combined resistance
of the driver air bag assembly, SRS coil assembly,
2–pin connector at the base of the steering column.
harness wiring CKTs IB05–YEL and IB06–YEL/BLK, and
connector terminal contact. 4. This test checks for proper contact and/or corrosion
of the 2–pin connector terminals at the base of
DTC Will Set When: steering column.
The combined resistance of the driver air bag assembly, 5. This test isolate the malfunction to one side of the
SRS Coil assembly, harness wiring CKTs IB05–YEL and SRS coil assembly yellow 2–pin connector located
IB06–YEL/BLK, and connector terminal contact is above at the base of the steering column.
a specified value. This test run once each ignition cycle 6. This test determines whether the malfunction is due
during the “Resistance Measurement Test” when: to high resistance in the wiring.
1. No “higher priority faults” are detected during 7. This test determines whether the malfunction is in
“Turn–ON” the SRS coil assembly or the driver air bag
2. “Ignition 1” voltage is in the specified value. assembly.
Diagnostic Aids: IB06–YEL/BLK. The test for this diagnostic trouble code
An intermittent condition is likely to be caused by a poor is only run while the “AIR BAG” warning lamp is
connection at terminals “1” and “2” of the SRS coil 2–pin performing the bulb check, unless DTC 17 or DTC 26 is
connector at the base of the steering column, terminal “1” detected. When a scan tool “Clear Codes” command is
and “2” of the driver air bag assembly 2–pin connector at issued and the malfunction is still present, the DTC will not
the top of the steering column, SDM terminals “3” and “4” reappear until the next ignition cycle.
or a poor wire to terminal connection in CKT IB05–YEL or
DTC 21 Driver Deployment Loop Resistance High

Step Action Yes No
1 Perform the “SRS Diagnostic System Check”. Repeat the “SRS
Diagnostic
Was the “SRS Diagnostic System Check” performed?
2. Use scan tool data list function, read and record the driver
Is driver resistance more than 3.7 ohms? Go to Step 3 Go to Chart A
3 1. Ignition switch “OFF.” Seat SRS coil
2. Disconnect SRS coil assembly yellow 2–pin connector located assembly 2–pin
at base of steering column is seated properly. connector
properly
Is the 2–pin connector connected properly?
4 1. Disconnect and inspect the SRS coil assembly yellow 2–pin
connector located base of steering column.
2. If ok, reconnect the SRS coil assembly yellow 2–Pin
connector.
2–pin connector located at the base of steering column and
appropriate adapter to SRS coil and passenger air bag
2. There has been a increase in the total circuit resistance of the
driver deployment loop.
checking CKTS IB05–YEL and IB06–YEL/BLK, and SDM
Replace SRS
connector terminal “3” and “4” to locate the root cause.
harness
DTC 21 Driver Deployment Loop Resistance High (Cont’d)

Step Action Yes No
2. Disconnect SRS driver / passenger load tool from SRS coil
assembly harness connector.
3. Connect SRS driver / passenger load tool J–41433 on the top
of steering column.
Ignition switch Ignition switch
4. Reconnect SRS coil assembly harness connector as the base
“OFF” “OFF”
of steering column.
Replace SRS coil Replace driver air
assembly bag assembly
mounted.
Repeat the “SRS
Diagnostic
DTC 22 Driver Deployment Loop Resistance Low
D09RW001

When the ignition switch is turned “ON”, the SDM will SDM turns “ON” the “AIR BAG” warning lamp and sets
perform tests to diagnose critical malfunctions within DTC 22.
are within their respective normal voltage ranges. The ignition switch is turned “OFF.”
The SDM then proceeds with the “Resistance
Measurement Test” “Driver Bag Low” terminal “4” is DTC Chart Test Description:
grounded through a current sink and the driver current Number(s) below refer to circled number(s) on the
source connected to “Driver Bag High” terminal “3” allows diagnostic chart:
a known amount of current to flow. By monitoring the 2. This test determines whether the malfunction is in
voltage difference between “Driver Bag High” and “Driver the SDM.
Bag Low” the SDM calculates the combined resistance of
the driver air bag assembly, SRS coil assembly, harness
2–pin connector at the base of the steering column.
wiring CKTs IB05–YEL and IB06–YEL/BLK and
connector terminal contact. 4. This test checks for proper operation of the shorting
clip in the yellow 2–pin connector.
DTC Will Set When: 5. This test isolate the malfunction to one side of the
The combined resistance of the driver air bag assembly, SRS coil assembly yellow 2–pin connector located
SRS Coil assembly, harness wiring CKTs IB05–YEL and at the base of steering column.
IB06–YEL/BLK and connector terminal contact is above a 6. This test determines whether the malfunction is due
specified value. This test is run once each ignition cycle to shortening in the wiring.
during the “Resistance Measurement Test” when: 7. This test determines whether the malfunction is in
1. No “higher priority faults” are detected during the SRS coil assembly or the driver air bag
“Turn–ON” assembly.
2. “Ignition 1” voltage is in the specified value.
Diagnostic Aids:
An intermittent condition is likely to be caused by a short
between CKT IB05–YEL or IB06–YEL/BLK or a
malfunctioning shorting clip on the driver air bag 17 or DTC 26 is detected. When a scan tool “Clear
assembly or SRS coil assembly which would require Codes” command is issued and the malfunction is still
replacement of the component. The test for this present, the DTC will not reappear until the next ignition
diagnostic trouble code is only run while the “AIR BAG” cycle.
warning lamp is performing the bulb check, unless DTC
DTC 22 Driver Deployment Loop Resistance Low

Step Action Yes No
1 Perform the “SRS Diagnostic System Check.” Go to the “SRS
Diagnostic
WAS THE “SRS Diagnostic System Check” performed?
2. Use scan tool data list function, read and record the driver
Is driver deployment loop resistance less than 1.7 ohms? Go to Step 3 Go to Chart A
3 1. Ignition switch “OFF.” Seat driver air
2. Make sure the SRS coil assembly yellow 2–pin connector bag assembly
located at the base of steering column is seated properly. 2–pin connector
properly
Is the 2–pin connector connected properly?
2. If ok, reconnect the SRS coil assembly yellow 2–pin
connector.
2. There has been a decrease in the total circuit resistance of the
driver deployment loop.
Replace SRS
harness
2. Disconnect SRS driver / passenger load tool from driver air
bag assembly harness connector.
3. Connect SRS driver / passenger load tool J–41433 to the top
of steering column 2–pin connector.
“OFF” “OFF”
of steering column.
mounted.
Go to the “SRS
Diagnostic
DTC 24 Driver Deployment Loop Short To Ground
D09RW001

When the ignition switch is turned “ON”, the SDM will Number(s) below refer to step number(s) on the
perform tests to diagnose critical malfunctions within diagnostic chart:
itself. Upon passing these tests, “Ignition 1”, and 2. This test determines whether the SDM is
deployment loop voltages are measured to ensure they malfunctioning
The SDM monitors the voltage at “Driver Bag Low” SRS coil assembly yellow 2–pin connector at the
terminal “4” and “passenger Bag Low” terminal “16” to base of the steering column.
detect shorts to ground in the air bag assembly circuits. 4. This test determines whether the malfunction is in
CKT IB05–YEL.
DTC Will Set When:
Neither of the two air bag assemblies is open. CKT IB06–YEL/BLK.
“Ignition 1” is within the normal operating voltage range.
This test is run once each ignition cycle and “Continuous 6. This test determines whether the malfunction is in
the SRS coil assembly or the driver air bag
Monitoring”. Once these conditions are met and the
assembly.
voltage at “Driver Bag Low” is below a specified value,
DTC 24 will set.
Diagnostic Aids:
Action Taken: An intermittent condition is likely to be caused by a short
SDM turns “ON” the “AIR BAG” warning lamp and sets a to ground in the driver air bag assembly circuit. Inspect
diagnostic trouble code. CKTs IB05–YEL and IB06–YEL/BLK carefully for cutting
or chafing.
The malfunction is no longer occurring and the ignition is
turned “OFF”.
DTC 24 Driver Deployment Loop Short To Ground

Step Action Yes No
Diagnostic
5. Read driver sense LO.
Is driver sense LO less than 1.5 volts? Go to Step 3 Go to Chart A
2. Disconnect SRS coil assembly yellow 2–pin connector located
at base of the steering column. leave passenger air bag
assembly connected.
appropriate adapter to SRS coil assembly harness connector.
4. ignition switch “ON.”
2. Disconnect SDM.
3. Disconnect SRS driver / passenger load tool.
4. Measure resistance on SDM harness connector “3” to terminal
Replace SRS
“6” (ground).
harness
Does J–39200 display “OL” (infinite)? Go to Step 5 Go to Step 7
5 measure resistance on SDM harness connector from terminal “4”
Replace SRS
to terminal “6” (ground).
harness
2. Disconnect SRS driver / passenger load tool J–41433 from
SRS coil assembly harness connector.
3. connect SRS driver / passenger load tool J–41433 and
appropriate adapter J–35616–A to driver air bag assembly
harness connector. located top of the steering column 2–pin
connector.
“OFF” “OFF”
of steering column.
mounted.
Go to the “SRS
Diagnostic
DTC 25 Driver Deployment Loop Short To Voltage
D09RW001
Circuit Description: 2. This test determines whether the SDM is

When the ignition switch is turned “ON”, the SDM will malfunctioning.
perform tests to diagnose critical malfunctions within 3. This test isolates the malfunction to one side of the
itself. Upon passing these tests, “Ignition 1”, and driver air bag assembly yellow 2–pin connector at
deployment loop voltages are measured to ensure they the base of steering column.
are within their respective normal voltage ranges. 4. This test determines whether the malfunction is in
The SDM monitors the voltage at “Driver Bag Low” CKT IB05–YEL.
terminal “4” and “Passenger Bag Low” terminal “16” to 5. This test determines whether the malfunction is in
detect shorts to B+ in the air bag assembly circuits. CKT IB06–YEL/BLK.
DTC Will Set When: the SRS coil assembly or the driver air bag
“Ignition 1” is in the normal operating voltage range. This assembly.
test is run once each ignition cycle and “Continuous
monitoring”. Once these conditions are met and the Diagnostic Aids:
voltage at “Driver Bag Low” is above a specified value, An intermittent condition is likely to be caused by a short
DTC 25 will set. to B+ in the driver air bag assembly circuit. Inspect CKTs
IB05–YEL and IB06–YEL/BLK carefully for cutting or
Action Taken: chafing. If the wiring pigtail of the driver air bag assembly
SDM turns “ON” the “AIR BAG” warning lamp and sets and SRS coil assembly is damaged, the components
DTC 25 and also DTC 71 must be replaced. A careful inspection of CKT IB05–YEL
and IB06–YEL/BLK, including the SRS coil assembly and
DTC Will Clear When: driver air bag assembly is essential to ensure that the
The SDM is replaced. replacement SDM will not be damaged.

diagnostic chart:
DTC 25 Driver Deployment Loop Short To Ignition

CAUTION: When DTC 25 has been set, it is necessary to replace the SDM. Setting DTC 25 will also cause DTC
71 to set. When a scan tool “CLEAR CODES” command is issued and the malfunction is no longer present,
DTC 71 will remain current. Ensure that the short to voltage condition is repaired prior to installing a
replacement SDM to avoid damaging the SDM.
Step Action Yes No

Diagnostic
Ignition switch “OFF.”
Connect scan tool data link connector. follow directions as
3. Read driver sense LO .
Is driver sense LO more than 3.5 volts? Go to Step 3 Go to Chart A
2. Disconnect SRS coil assembly yellow 2–pin connector at the
base of the steering column. leave passenger air bag
assembly connected.
3. Connect SRS driver /passenger load tool J–41433 and
appropriate adapter to SRS coil assembly harness connector.
Is driver sense LO more than 3.5 volts? Go to Step 4 Go to Step 6
2. Disconnect SDM.
3. Disconnect SRS driver /passenger load tool.
4. Measure resistance on SDM harness connector “3” to terminal
Replace SRS
“12” (ignition).
harness
Does J–39200 display “OL” (infinite)? Go to Step 5 Go to Step 7
5 Measure resistance on SDM harness connector from terminal “4”
Replace SRS
to terminal “12” (ignition).
harness
2. Disconnect SRS driver / passenger load tool J–41433 and
appropriate adapter J–35616–A to driver air bag assembly
harness 2-pin connector located at top of the steering column.
“OFF” “OFF”
of steering column.
Is driver sense LO more than 3.5 volts? Go to Step 7 Go to Step 7
Ignition switch
mounted.
“OFF”
Replace SDM
Is passenger senslo less than 3.5 volts? Go to Step 8 Go to Chart A
mounted.
Go to the “SRS
Diagnostic
DTC 26 Driver Deployment Loop Open
D09RW001
Circuit Description: specified value for 500 milliseconds during “Continuous

When the ignition switch is turned “ON”, the SDM will Monitoring”.
perform tests to diagnose critical malfunctions within
deployment loop voltages are measured to ensure they Number(s) below refer to step number(s) on the
are within their respective normal voltage ranges. diagnostic chart:
During “Continuous Monitoring” diagnostics, a fixed 2. This test determines whether the malfunction is in
amount of current is following in the deployment loop. the SDM.
This produces proportional voltage drops in the loop. By 3. This test verifies proper connection of the yellow
monitoring the voltage difference between “Driver Bag 2–pin connector at the base of the steering column.
High” and “Driver Bag Low”, the SDM calculates the 4. This test checks for proper contact and/or corrosion
combined resistance of the driver air bag assembly, SRS of the yellow 2–pin connector at the base of the
coil assembly, harness wiring CKTs IB05–YEL and steering column.
IB06–YEL/BLK, and connector terminal contact. 5. This test isolates the malfunction to one side of the
SRS coil assembly yellow 2–pin connector located
DTC Will Set When: at the base of steering column.
The voltage difference between “Driver Bag High” 6. This test determines whether the open is in the
terminal “3” and “Driver Bag Low” terminal “4” is above or wiring.
equal to a specified value for 500 milliseconds during
“Continuous Monitoring”. the SRS coil assembly or the driver air bag
assembly.
Action Taken:
SDM turns “ON” the “AIR BAG” warning lamp and sets a Diagnostic Aids:
An intermittent condition is likely to be caused by a poor
DTC Will Clear When: connection at the driver air bag assembly harness 2–pin
connector terminals “1” and “2” at the top of the steering
The voltage difference between “Driver Bag High” column, SRS coil assembly harness 2–pin connection
terminal “3” and “Driver Bag Low” terminal “4” is below a terminals “1” and “2”, SDM terminals “3” and “4”, or an
open in CKTs IB05–YEL and IB06–YEL/BLK.
DTC 26 Driver Deployment Loop Open

Step Action Yes No
Diagnostic
2 1. When measurements are requested in this chart use J-39200
2. use scan tool data list function, read and record the driver
differential voltage.
Is driver VDIF more than 4 volts? Go to Step 3 Go to Chart A
Seat driver air
2. Make sure the SRS coil assembly yellow 2–pin connector
bag assembly
located at the base of steering column is seated properly.
2–pin connector
Is the yellow 2–pin connector connected properly? Go to Step 4 Go to Step 8
2. If ok, reconnect the SRS coil assembly yellow 2–pin
connector.
3. Connect SRS driver/passenger load tool J–41433 and
2. there has been an open circuit in the driver inflator deployment
loop.
3. use the high resolution ohmmeter mode of the DVM while
Replace SRS
harness
2. Disconnect SRS driver / passenger load tool from SRS coil
assembly harness connector.
3. connect SRS driver / passenger load tool J–41433 on steering
column 2–pin connector.
4. Reconnect SRS coil assembly harness connector at the base
“OFF” “OFF”
of steering column.
IS DTC 26 CURRENT? Go to Step 8 Go to Step 8
mounted.
Repeat the “SRS
Diagnostic
DTC 51 Deployment Event Commanded
D09RW001

The SDM contains a sensing device which converts SDM turns “ON” the “AIR BAG” warning lamp records
vehicle velocity changes to an electrical signal. The “Crash Data”, and sets a diagnostic trouble code.
electrical signal generated is processed by the SDM and
then compared to a value stored in memory. When the DTC Will Clear When:
generated signal exceeds the stored value, the SDM will The SDM is replaced.
cause current to flow through the air bag assembly
deploying the air bags and causing DTC 51 to set. DTC Chart Test Description:
DTC Will Set When: diagnostic chart:
The SDM detects a frontal crash, up to 30 degrees off the 2. If air bag assembly (s) has not deployed, DTC 51
centerline of the vehicle, of sufficient force to warrant may have falsely set.
deployment of the air bags. 3. If DTC 51 has set with no signs of frontal impact, the
diagnostic trouble code has falsely set.
DTC 51 Deployment Event Commanded

PERSONAL INJURY.
Step Action Yes No

Diagnostic
2 Ignition switch “OFF.” Replace
components and
Have air bag assemblies deployed?
perform
inspections as
directed in
“repairs and
inspections
required after an
accident” in this
section
clear diagnostic
trouble codes
Repeat “SRS
Diagnostic
System Check” Go to Step 3
3 Inspect front of vehicle and undercarriage for sings of impact. Replace
components and
Were signs of impact found?
perform Ignition switch
inspections as “OFF”
directed in Replace SDM
“Repairs and Reconnect all
Inspections SRS system
Required After An components,
Accident” in this ensure all
section components are
Clear diagnostic properly
trouble codes mounted
Repeat “SRS Repeat “SRS
Diagnostic Diagnostic
System Check” System Check”
DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy

Reserves Out Of Range
D09RW001

The SDM contains a sensing drive which converts vehicle SDM turns “ON” the “AIR BAG” warning lamp records
velocity changes to an electrical signal. The electrical “Crash Data”, and sets a diagnostic trouble code.
signal generated is processed by the SDM and then
compared to a value stored in memory. When the DTC Will Clear When:
generated signal exceeds the stored value, the SDM will The SDM is replaced. If DTC 53 is set, one or more DTCs
cause current to flow through the air bag assembly will be set in addition to DTC 53. Malfunction(s) setting
deploying the air bags. DTC 53 is set accompanying with DTC(s) (other than DTC 71) must be repaired so that
DTC 51 when a deployment occurs while an air bag DTC(s) will not be set when a new SDM is installed.
assembly circuit fault is present that could possible result
in a no deployment situation in one or both air bag DTC Chart Test Description:
assemblies. Number(s) below refer to step number(s) on the
diagnostic chart:
DTC Will Set When: 2. If air bag assembly have not deployed, DTC 53 may
The SDM detects a frontal crash, up to 30 degrees off the have falsely set.
centerline of the vehicle, of sufficient force to warrant 3. If DTC 53 has set with no signs of frontal impact, the
deployment of the air bags and an inflator circuit fault is diagnostic trouble code has falsely set.
present..
DTC 53 Deployment Commanded WITH Deployment Loop Fault Or Energy Reserves Out
Of Range
PERSONAL INJURY.
Step Action Yes No

Diagnostic
2 Ignition switch “OFF.” Replace
components and
Have air bag assembles deployed?
perform
inspections as
directed in
“Repairs And
Inspections
Required After An
Accident” in this
section
Clear diagnostic
trouble codes
Repeat the “SRS
Diagnostic
System Check” Go to Step 3
3 Inspect front of vehicle and undercarriage for signs of impact. Replace
components and
Were signs of impact found?
perform Ignition switch
inspections as “OFF”
directed in Replace SDM
“Repairs And Reconnect all
Inspections SRS system
Required After An components,
Accident” in this ensure all
section components are
Clear diagnostic properly
trouble codes mounted
Repeat “SRS Repeat the “SRS
Diagnostic Diagnostic
System Check” System Check”
DTC 61 Warning Lamp Circuit Failure
D09RW001
Circuit Description: the commanded state of the lamp driver for 500
When the ignition switch is turned “ON”, battery voltage is milliseconds. This test is run every 100 milliseconds
applied to the “AIR BAG” warning lamp and to the “Ignition during “Continuous Monitoring” tests and once per each
1” input terminal “12”. The SDM responds by flashing the ignition cycle at the beginning.
“AIR BAG” warning lamp seven times. The SDM
monitors the lamp driver output by comparing the output
Action Taken:
state at “SRS Warning Lamp” terminal “7” to the SDM attempts to turn “ON” the “AIR BAG” warning lamp
microprocessor commanded state. When “Ignition 1” is in and sets a diagnostic trouble code.
the specified value, and the output state does not match
the commanded state of the lamp driver for 500 DTC Will Clear When:
milliseconds, DTC 61 is set. The ignition switch is turned “OFF.”
DTC Will Set When: Diagnostic Aids:

“Ignition 1” voltage is in the specified value and the output Refer to Charts B and C to diagnose warning lamp circuit
state at the “SRS Warning Lamp” terminal does not match malfunctions.
DTC 61 Warning Lamp Circuit Failure

Step Action Yes No
Diagnostic
Go to Step 2 System Check.”
2 1. Malfunctions within the “AIR BAG” warning lamp circuitry will
set this diagnostic trouble code.
2. These malfunctions are addressed in the “SRS Diagnostic
System Check” via Chart B and Chart C.
3. Failure to properly perform the “SRS Diagnostic System
Check” may result in misdiagnosis.
Ignition switch Repeat the “SRS
5. Clear SRS diagnostic trouble codes.
“OFF.” Diagnostic
IS DTC 61 set? Go to Chart A. System Check.”
DTC 71 Internal SDM Fault
D09RW001
Circuit Description: DTC Will Set When:

DTC 71 is an indication of a potential internal SDM Any of the above indicated malfunctions are detected by
malfunction and will set if any of the following conditions the SDM. The malfunctions described above are tested
are detected: mainly during “Continuous Monitoring” and some ones
1) Deployment or microprocessor energy reserve failure. run each ignition cycle.
2) EEPROM failure.
3) ROM failure. Action Taken:
4) RAM failure. SDM turns “ON” the “AIR BAG” warning lamp and sets a
5) Calibration check sum failure. diagnostic trouble code.
6) Deployment switch faults.
7) Accelerometer fault. DTC Will Clear When:
8) Arming sensor fault. A scan tool “Clear Codes” commanded is received by the
9) Diagnostic current faults. SDM. Some of the indicated malfunctions will only allow
10) DTC 19 the “AIR BAG” warning lamp to go out.
11) DTC 25 But when DTC 19, 25, 51, 53 are also set, SDM is
12) DTC 51 replaced.
13) DTC 53
DTC 71 Internal SDM Fault

PERSONAL INJURY.
CAUTION: When DTC 19 or 25 has been set, it is necessary to replace the SDM. Setting DTC 19 and 25 or 51
or 53 will also cause DTC 71 to set. When a scan tool “CLEAR CODES” command is issued and the
malfunction is no longer present, DTC 51 or 53 and DTC 71 will remain current. Ensure that the short to voltage
condition DTC 19, 25 is repaired prior to installing a replacement SDM to avoid damaging the SDM.
Step Action Yes No

Diagnostic
2 Note SRS “Diagnostic System Check.” Go to DTC 19 if
DTC 19 is set
Is DTC 19 or 25 or 51 or 53 also set (CURRENT OR HISTORY)?
Go to DTC 25 if Ignition switch
(refeer to notice above.)
DTC 25 is set “OFF”
Go to DTC 51 if Replace SDM
DTC 51 is set Repeat the “SRS
Go to DTC 53 if Diagnostic
DTC 53 is set System Check”
CRUISE CONTROL SYSTEM 10A–1
TROOPER
CONTROL SYSTEM
CRUISE CONTROL SYSTEM
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . 10A–1 Cruise Control Main Switch . . . . . . . . . . . . . . . 10A–5
Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A–2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A–5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A–2 Cruise Control Switch (Combination Switch) 10A–5
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A–3 Removal and Installation . . . . . . . . . . . . . . . 10A–5
Clutch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A–3 Powertrain Control Module (PCM) . . . . . . . . . 10A–5
Removal and Installation . . . . . . . . . . . . . . . 10A–3 Removal and Installation . . . . . . . . . . . . . . . 10A–5
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A–3 Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A–5
Starter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A–4 Removal and Installation . . . . . . . . . . . . . . . 10A–5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A–4 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A–6

WARNING: THIS VEHICLE HAS A SUPPLEMENTAL The cruise control keeps the vehicle running at a fixed
RESTRAINT SYSTEM (SRS). REFER TO THE SRS speed until a signal canceling this fixed speed is received .
COMPONENT AND WIRING LOCATION VIEW IN When the main switch “AUTO CRUISE” is turned on with
ORDER TO DETERMINE WHETHER YOU ARE the vehicle in the running mode, the battery voltage is
PERFORMING SERVICE ON OR NEAR THE SRS applied to the control unit. When a signal from the control
COMPONENTS OR THE SRS WIRING. WHEN YOU switch is input to the PCM while the vehicle is in this state,
ARE PERFORMING SERVICE ON OR NEAR THE SRS the cruise control system is activated. Also, while the
COMPONENTS OR THE SRS WIRING, REFER TO system is operating, the “AUTO CRUISE” indicator light in
THE SRS SERVICE INFORMATION. FAILURE TO the meter assembly lights up.
FOLLOW WARNINGS COULD RESULT IN POSSIBLE 1. SET/COAST Switch Function
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR 1. Set Function: When the SET/COAST switch is
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. pressed and released with the main switch on, the
CAUTION: Always use the correct fastener in the speed at which the vehicle is running at that moment
proper location. When you replace a fastener, use is stored in the memory, and the vehicle automatically
ONLY the exact part number for that application. runs at the stored speed.
ISUZU will call out those fasteners that require a 2. Coast-down Function: When the SET/COAST
replacement after removal. ISUZU will also call out switch is kept on while the vehicle in running, the
the fasteners that require thread lockers or thread vehicle decelerates during that time. The speed at
sealant. UNLESS OTHERWISE SPECIFIED, do not which vehicle is running when the control switch is
use supplemental coatings (Paints, greases, or other turned off is stored in the memory, and the vehicle
corrosion inhibitors) on threaded fasteners or automatically returns to the stored speed.
fastener joint interfaces. Generally, such coatings 3. Tap-down Function: When the SET/COAST switch
adversely affect the fastener torque and the joint is turned on and off instantaneously while the vehicle
clamping force, and may damage the fastener. When is running, the vehicle decelerates a mile for each
you install fasteners, use the correct tightening on/off operation. The vehicle speed at which the
sequence and specifications. Following these vehicle was running when the SET/COAST was
instructions can help you avoid damage to parts and turned off last is stored in the memory, and the vehicle
systems. automatically returns to this stored speed.
10A–2 CRUISE CONTROL SYSTEM
2. RESUME/ACCEL Switch Function 3. CANCEL Function

1. Resume Function: When the RESUME/ACCEL 1. Temporary Cancellation:
switch is turned on/off after the system is temporarily D When the cancel switch is turned on.
deactivated by pressing the brake or clutch pedal
D When the brake pedal is pressed.
while the vehicle is running, the vehicle resumes the
speed stored before the system was released, and D When the clutch pedal is pressed. (M/T)
the vehicle automatically runs at the stored speed . D When the select lever is shifted to any position other
2. Accelerate Function: When the RESUME/ACCEL than “D”, “3”, “2” or “L”. (A/T)
switch is kept on after the system is released D When the cancel switch is operated.
completely, the vehicle accelerates its speed during D When the vehicle speed exceeds about 12.5mph
that time. The vehicle speed at which the vehicle was over the vehicle speed stored in the memory.
running when the switch was turned off is stored in the
memory, and the vehicle automatically returns to this D Turning the RESUME/ACCEL switch will return the
speed. vehicle to the speed stored in the cruise control
memory.
3. Tap-up Function: When the RESUME/ACCEL
switch is turned on and off instantaneously while the D When the vehicle speed gets lower than 20 mph (32
vehicle is running, the vehicle accelerates a mile for km/h).
each on/off operation. The vehicle speed at which the 2. Complete Cancellation:
vehicle was running when the switch was turned off D When the starter switch or the main switch is turned
last is stored in the memory, and the vehicle off.
automatically returns to this stored speed. D When the fail-safe function is activated.
D When the vehicle speed is about 24 mph.
Brake Switch
2. Remove the brake switch (1).
1. Check to see if the brake pedal has been returned by
D Disconnect the connector.
D Loosen the lock nuts of the switch. 2. Turn the switch clockwise until the tip of the threaded
D Remove the switch by turning it. portion of the brake switch contacts the pedal arm.
3. Turn the switch counterclockwise until the space
arm is 0.5 to 1.0 mm (0.02-0.04 in.) as shown in the
figure.
310RS004
310RS003
Adjustment
1. Check to be sure that the brake pedal (3) has been
completely returned by the return spring.
2. Disconnect the switch connector.
3. Loosen the lock nut (1) of the switch (2).
4. Turn the switch clockwise until the tip of screw portion
of the brake pedal hits the pedal arm.
5. Turn the switch counterclockwise until the clearance
between the tip of the screw portion and the pedal arm
becomes 0.5 to 1.0 mm (0.02-0.04 in).
6. Tighten the lock nut.
7. Connect the switch connector.
310RW006
Clutch Switch
Removal and Installation Adjustment
Refer to the Clutch Control removal and installation steps 1. Check to be sure that the clutch pedal (1) has been
in Clutch section. completely returned by the return spring.
2. Disconnect the switch connector.
3. Loosen the lock nut (2) of the switch (3).
4. Push the switch by hand until the push rod cannot be
seen from the tip portion of the switch.
5. Give the switch one reverse rotation.
6. Tighten the lock nut.
7. Connect the switch connector.
203RW002
Starter Switch
2. Remove the front console assembly (1). Refer to the
Instrument Panel Assembly in Body Structure 1. When installing the steering cowl (10), be sure to pass
section. the harnesses through the route as shown in the
figure so that the starter switch harness (7), the
3. Remove the lower cluster assembly (2). Refer to the
combination switch harness (8) and the inflator
Instrument Panel Assembly in Body Structure
module harness (9) will not catch.
section.
assembly (3). Refer to the Instrument Panel
Assembly in Body Structure section.
821RW024
5. Remove seven screws to remove the steering cowl

(6).
6. Disconnect the connector, remove the screw (4) and
then remove the starter switch (5).
825RW058
431RW005
Cruise Control Main Switch

Removal 5. Remove the instrument panel cluster assembly (5).
1. Disconnect the battery ground cable. Structure section.
2. Remove the front console assembly (1). Refer to the 6. Disconnect the and push the lock from the side of the
Instrument Panel Assembly in Body Structure instrument panel cluster assembly to remove the
section. cruise control main switch (4).
3. Remove the lower cluster assembly (2). Refer to the
Instrument Panel Assembly in Body Structure
section.
assembly (3). Refer to the Instrument Panel
Assembly in Body Structure section.
821RW079
Installation
821RW024
1. Push in the switch with your fingers until the switch is
locked securely.
Cruise Control Switch (Combination Switch)

Refer to the Lighting Switch (Combination Switch)
removal and installation steps of Lighting System in Body
and Accessories section.

Refer to Powertrain Control Module (PCM) in Engine
section.
Mode Switch
Refer to the Mode Switch removal and installation steps
in Automatic Transmission section.
Diagnosis
Cruise control system is controlled by the PCM as well as
6VE1 engine and automatic transmission. DTC codes are
stored in the PCM if troubles occur in the circuit. DTC
codes categorized “type D” are shown only by the Tech 2
scan tool. The following chart only shows some typical
DTCs for cruise control system. Refer to PCM Diagnostic
Trouble Codes in Driveability and Emissions for entire
DTC diagnosis.
TROUBLE DTC MAJOR CONDITION OF
DTC DIAGNOSIS PERIOD
PART TYPE TROUBLE
P0565 CRUISE MAIN D D THE SWITCH CONTACT DIAGNOSIS IS ENABLED IN
CIRCUIT REMAINS ON FOR 15 130 SECONDS AFTER THE
SECONDS OR MORE. SWITCH OPERATED.
D NOISES ARE GENERATED
BY THE POOR SWITCH
CONTACT 60 TIMES WITHIN
1 SECOND.
P0566 CRUISE CAN- D D THE SWITCH CONTACT DIAGNOSIS IS ENABLED IN
CEL CIRCUIT REMAINS ON FOR 40 120 SECONDS AFTER THE
BY THE POOR SWITCH
CONTACT 100 TIMES
WITHIN 1.6 SECONDS.
P0567 CRUISE RE- D D THE SWITCH CONTACT DIAGNOSIS IS ENABLED IN
SUME CIRCUIT REMAINS ON FOR 50 110 SECONDS AFTER THE
BY THE POOR SWITCH
CONTACT 100 TIMES
WITHIN 1.6 SECONDS.
P0568 CRUISE SET D D THE SWITCH CONTACT DIAGNOSIS IS ENABLED IN
CIRCUIT REMAINS ON FOR 120 125 SECONDS AFTER THE
BY THE POOR SWITCH
CONTACT 100 TIMES
WITHIN 1.6 SECONDS.
DTC: Diagnostic Trouble Code

NOTE: The DTCs are detected while the engine is
running
RODEO(UE)
CONTENTS
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A
Maintenance and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section.1
HVAC System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section.2
Power–Assisted Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A
Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C
Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D
Wheel and Tire System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E
Intelligent Suspension System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F
DRIVELINE/AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section.4
Differential (Front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A1
Differential (Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A2
Driveline Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B
Drive Shaft System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4C
Transfer Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4D
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section.5
Brake Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A
Anti–lock Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B
Power-Assisted Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5C
Parking Brakes (4x4 Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D
Parking Brakes (4x2 Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5D
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section.6
Engine Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6A
Engine Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B
Engine Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C
Engine Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D1
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D2
Starting and Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D3
Driveability and Emissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6E
Engine Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F
Engine Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6G
Engine Speed Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6H
Inducton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6J
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section.7
Automatic Transmission (4L30–E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A
Transmission Control System (4L30–E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A1
Manual Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C
Ligting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A
Wiper / Washer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B
Entertainment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C
Wiring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D
Meter and Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E
Body Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F
Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8G
Security and Locks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H
Sunroof / Convertible Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8I
Exterior / Interior Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J
RESTRAINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section.9
Seat Belt System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A
Supplemental Restraint System (SRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J
Restraint Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J1
CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section.10
Cruise Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A
RODEO
GENERAL INFORMATION
CONTENTS
General Information . . . . . . . . . . . . . . . . . . . . . 0A
Maintenance and Lubrication . . . . . . . . . . . . . 0B
General Information
CONTENTS
General Repair Instruction . . . . . . . . . . . . . . . . 0A–1 Lifting Instructions . . . . . . . . . . . . . . . . . . . . . . . 0A–11
Illustration Arrows . . . . . . . . . . . . . . . . . . . . . . . 0A–2 Standard Bolts Torque Specifications . . . . . . 0A–13
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A–3 Abbreviations Charts . . . . . . . . . . . . . . . . . . . . 0A–14
Theft Prevention Standard . . . . . . . . . . . . . . . . 0A–6 Service Parts Identification Plate . . . . . . . . . . 0A–15
General Repair Instruction 13. When removing or replacing parts that require
refrigerant to be discharged from the air conditioning
1. If a floor jack is used, the following precautions are system, be sure to use the Vehicle Refrigerant
recommended. Recovery and Recycling Equipment (VRRRE) to
Park vehicle on level ground, “block” front or rear recover and recycle Refrigerant–134a.
wheels, set jack against the recommended lifting 14. When a service operation is completed, make a final
points (see “Lifting Instructions” in this section), raise check to be sure the service has been done properly
vehicle and support with chassis stands and then and the problem has been corrected.
perform the service operations.
15. SUPPLEMENTAL RESTRAINT SYSTEM
2. Before performing service operations, disconnect The vehicle is equipped with a Supplemental
ground cable from the battery to reduce the chance of Restraint System (SRS) – Air Bags. This system is
cable damage and burning due to short circuiting. not to be serviced without consulting the appropriate
3. Use a cover on body, seats and floor to protect them service information. Consult Section 9J “SRS
against damage and contamination. System” if work is to be done on the front of the
4. Brake fluid and anti–freeze solution must be handled vehicle such as bumper, sheet metal, seats, wiring,
with reasonable care, as they can cause paint steering wheel or column. Also review SRS system
damage. information if any arc welding is to be done on the
vehicle. The SRS system equipped vehicle can be
5. The use of proper tools and recommended essential
identified by:
and available tools, where specified, is important for
efficient and reliable performance of service repairs. 1. “AIR BAG” warning light on the instrument
6. Use genuine Isuzu parts. cluster.
7. Used cotter pins, plastic clips, gaskets, O–rings, oil 2. A Code “K” or “M” for fifth digit of Vehicle
seals, lock washers and self–locking nuts should be Identification Number.
discarded and new ones should be installed, as
normal function of the parts cannot be maintained if
these parts are reused.
8. To facilitate proper and smooth reassembly
operation, keep disassembled parts neatly in groups.
Keeping fixing bolts and nuts separate is very
important, as they vary in hardness and design
depending on position of installation.
9. Clean the parts before inspection or reassembly. Also
clean oil ports, etc. using compressed air, and make
certain they are free from restrictions.
10. Lubricate rotating and sliding faces of the parts with
oil or grease before installation.
11. When necessary, use a sealer on gaskets to prevent
leakage.
12. Carefully observe all specifications for bolt and nut
torques.
Illustration Arrows
Arrows are designed for specific purposes to aid your understanding of technical illustrations.
Arrow Type Application Arrow Type Application
D Ambient/Clean air
Front of vehicle flow
D Cool air flow
D Gas other than

Up Side ambient air
D Hot air flow
D Ambient air mixed

with another gas
Task Related
D Can indicate
temperature change
View Detail Motion or direction
Lubrication point oil or

View Angle
fluid
Dimension (1:2) Lubrication point grease
Sectioning (1:3) Lubrication point jelly

Identification
Vehicle Identification Number (VIN)
This is the legal identification of the vehicle. it is located on
the left bottom of the windshield. It can be easily seen
through the windshield from outside the vehicle.
710RW003
Engine Serial Number Transmission Serial Number
D 6VD1 Engine Manual : Stamped on the left side of the transmission
The gasoline engine serial number is stamped on the left intermediate plate.
rear lower area of the cylinder block above the starter.
220RS025
F06RW001
D X22SE Engine
The gasoline engine serial number is stamped on the rear
end raised area of the cylinder block left side.
035RW022
Automatic : Stamped on the identification plate, located
on the left side of the transmission above the mode
switch.
240RY00040
Theft Prevention Standard

The 11 major components listed below will be marked
with 17 digit VIN at the stage of production. In addition its
service parts will be marked with manufacturer’s trade
mark, “R” mark and “DOT” mark.
Reference INDICATION
COMPONENT
Figure No. PRODUCTION SERVICE PARTS
0A-10 ENGINE 1– 6VD1 VIN plate
– X22SE
0A-11 TRANSMISSION 2– Manual transmission VIN plate

– Automatic transmission
0A-11 BODY 3– Engine hood VIN label

4– Front door
5– Rear door
6– Fender
7– Rear Quarter panel
8– Front bumper
9– Back door left side
10– Back door right side
11– Rear bumper
Anti Theft Stamping/Plate/Label

STAMPING/PLATE LABEL
PRODUCTION
SERVICE PARTS
Anti Theft Stamping/Label/Plate Location
The stamping, label and plate locations are indicated by
arrows in the illustration below.
NOTE:
1. VIN plate locations for production.
2. Stamping locations for service parts.
Engine (6VD1)
901RW080
Engine (X22SE)
035RW025
Manual Transmission (MUA)
901RW081
Automatic Transmission (THM)
901RW082–1
Body
604RW023
Body Label Instructions
Do not peel off the masking tape until completion of paint
work when replacing these parts, as the tape is affixed on
the label attached to service parts for body of the
anti–theft component.
NOTE: Be sure to pull off the masking tape after paint
work has been completed.
Do not attempt to remove this label for any reason.
901RW083
Precautions in pulling off the masking tape

1. Use only your finger nail or a similar blunt instrument
to peel off the masking tape. Use of a sharp object will
damage the underlying anti–theft label.
2. Be careful not to damage the paint around the label.
901RW084
Lifting Instructions
CAUTION: D When jacking or lifting a vehicle at the frame side
D If a lifting device other than the original jack is rail or other prescribed lift points, be certain that
used, it is most important that the device be lift pads do not contact the catalytic converter,
applied only to the correct lifting points. Raising brake pipes or cables, or fuel lines. Such contact
the vehicle from any other point may result in may result in damage or unsatisfactory vehicle
serious damage. performance.
Lifting Points and Supportable Point Locations
C00RX002
Lifting Point: Front

D When using a floor jack, lift on the Convex portion of
the skid plate.
545RS001
Supportable Point: Front Supportable Point: Rear
D Position the chassis stands at the bottom of the frame D Position the chassis stands at the bottom of the frame
sidemember, behind the front wheel. sidemember, just behind the trailing link bracket.
501RS003 501RW002
Lifting Point: Rear Legend

D Position the floor jack at the center of the rear axle (1) Trailing Link Bracket
case when lifting the vehicle.
Supportable Point: Rear
D Position the chassis stands at the bottom of the rear
axle case.
420RS002
420RS001
Standard Bolts Torque Specifications

The torque values given in the following table should be
applied where a particular torque is not specified.
4.8 8.8 9.8
Strength Class
Refined Non-Refined
Bolt
Identification
Bolt Diameter ×
Pitch (mm)
M 6X1.0 4 – 8 N·m (3 – 6 lb ft) 5 – 10 N·m (4 – 7 lb ft) –
M 8X1.25 8 – 18 N·m (6 – 13 lb ft) 12 – 23 N·m (9 – 17 lb ft) 17 – 30 N·m (12 – 22 lb ft)
M 10X1.25 21 – 34 N·m (15 – 25 lb ft) 28 – 46 N·m (20 – 34 lb ft) 37 – 63 N·m (27 – 46 lb ft)
* M10X1.5 20 – 33 N·m (14 – 25 lb ft) 28 – 45 N·m (20 – 33 lb ft) 36 – 60 N·m (27 – 44 lb ft)
M12X1.25 49 – 74 N·m (36 – 54 lb ft) 61 – 91 N·m (45 – 67 lb ft) 76 – 114 N·m (56 – 84 lb ft)
The asterisk * indicates that the bolts are used for

female–threaded parts that are made of soft materials
such as casting, etc.
Abbreviations Charts Exh — Exhaust

° F — Degrees Fahrenheit
List of automotive abbreviations which may be used Fed — Federal (All States Except Calif.)
in this manual FF — Front Drive Front Engine
A — Ampere(s) FL — Fusible Link
ABS — Antilock Brake System FLW — Fusible Link Wire
AC — Alternating Current FP — Fuel Pump
A/C — Air Conditioning FRT — Front
ACCEL — Accelerator ft — Foot
ACC — Accessory FWD — Front Wheel Drive
ACL — Air Cleaner 4WD — Four Wheel Drive
Adj — Adjust 4 x 4 — Four Wheel Drive
A/F — Air Fuel Ratio 4 A/T — Four Speed Automatic Transmission/Transaxle
AIR — Secondary Air Injection System Gal — Gallon
Alt — Altitude GEN — Generator
AMP — Ampere(s) GND — Ground
ANT — Antenna Gov — Governor
ASM — Assembly g — Gram
A/T — Automatic Transmission/Transaxle Harn — Harness
ATDC — After Top Dead Center HC — Hydrocarbons
ATF — Automatic Transmission Fluid HD — Heavy Duty
Auth — Authority Hg — Hydrargyrum (Mercury)
Auto — Automatic HiAlt — High Altitude
BARO — Barometric Pressure HO2S — Heated Oxygen Sensor
Bat — Battery HVAC — Heater–Vent–Air–Conditioning
B+ — Battery Positive Voltage IAC — Idle Air Control
Bbl — Barrel IAT — Intake Air Temperature
BHP — Brake Horsepower IC — Integrated Circuit / Ignition Control
BPT — Backpressure Transducer ID — Identification / Inside Diameter
BTDC — Before Top Dead Center IGN — Ignition
° C — Degrees Celsius INJ — Injection
CAC — Charge Air Cooler IP — Instrument Panel
Calif — California IPC — Instrument Panel Cluster
cc — Cubic Centimeter Int — Intake
CID — Cubic Inch Displacement ISC — Idle Speed Control
CKP — Crankshaft Position J/B — Junction Block
CL — Closed Loop kg — Kilograms
CLCC — Closed Loop Carburetor Control km — Kilometers
CMP — Camshaft Position km/h — Kilometer per Hour
CO — Carbon Monoxide kPa — Kilopascals
Coax — Coaxial kV — Kilovolts (thousands of volts)
Conn — Connector kW — Kilowatts
Conv — Converter KS — Knock Sensor
Crank — Crankshaft L — Liter
Cu. In. — Cubic Inch lb ft — Foot Pounds
CV — Constant Velocity lb in — Inch Pounds
Cyl — Cylinder(s) LF — Left Front
DI — Distributor Ignition LH — Left Hand
Diff — Differential LR —Left Rear
Dist — Distributor LS — Left Side
DLC — Data Link Connector LWB — Long Wheel Base
DOHC — Double Overhead Camshaft L–4 — In–Line Four Cylinder Engine
DTC — Diagnostic Trouble Code MAF — Mass Air Flow
DTM — Diagnostic Test Mode MAN — Manual
DTT — Diagnostic Test Terminal MAP — Manifold Absolute Pressure
DVM — Digital Voltmeter (10 meg.) Max — Maximum
DVOM — Digital Volt Ohmmeter MC — Mixture Control
EBCM — Electronic Brake Control Module MFI — Multiport Fuel Injection
ECM — Engine Control Module MIL — Malfunction Indicator Lamp
ECT — Engine Coolant Temperature Min — Minimum
EEPROM — Electronically Erasable Programmable mm — Millimeter
Read Only Memory MPG — Miles Per Gallon
EGR — Exhaust Gas Recirculation MPH — Miles Per Hour
EI — Electronic Ignition M/T — Manual Transmission/Transaxle
ETR — Electronically Tuned Receiver MV — Millivolt
EVAP — Evaporation Emission
N — Newtons TVRS — Television & Radio Suppression
NA — Natural Aspirated TVV — Thermal Vacuum Valve
NC — Normally Closed TWC — Three Way Catalytic Converter
N·M — Newton Meters 3 A/T — Three Speed Automatic Transmission/Transaxle
NO — Normally Open 2WD — Two Wheel Drive
NOX — Nitrogen, Oxides of 4 x 2 — Two Wheel Drive
OBD — On-Board Diagnostic U–joint — Universal Joint
OD — Outside Diameter V — Volt(s)
O/D — Over Drive VAC — Vacuum
OHC — Overhead Camshaft VIN — Vehicle Identification Number
OL — Open Loop VRRRE — Vehicle Refrigerant Recovery and Recycling
O2 — Oxygen Equipment
O2S — Oxygen Sensor V–ref — ECM Reference Voltage
PAIR — Pulsed Secondary Air Injection System VSS — Vehicle Speed Sensor
P/B — Power Brakes VSV — Vacuum Switch Valve
PCM — Powertrain Control Module V–6 — Six Cylinder “V” Engine
PCV — Positive Crankcase Ventilation V–8 — Eight Cylinder ”V” Engine
PRESS — Pressure W — Watt(s)
PROM — Programmable Read Only Memory w/ — With
PNP — Park/Neutral Position w/b — Wheel Base
P/S — Power Steering w/o — Without
PSI — Pounds per Square Inch WOT — Wide Open Throttle
PSP — Power Steering Pressure
Pt. — Pint
Pri — Primary Service Parts Identification Plate
PWM — Pulse Width Modulate The Vehicle Information Plate (Service Parts ID plate) is
Qt. — Quart provided on all vehicle models.
REF — Reference It is located on the center dash wall inside the engine
RF — Right Front compartment. The plate lists the VIN (Vehicle
RFI — Radio Frequency Interference Identification Number), paint information and all
RH — Right Hand production options and special equipment on the vehicle
RPM — Revolutions Per Minute when it was shipped from the factory.
RPM Sensor — Engine Speed Sensor
RPO — Regular Production Option
RR — Right Rear
RS — Right Side
RTV — Room Temperature Vulcanizing
RWAL — Rear Wheel Antilock Brake
RWD — Rear Wheel Drive
SAE — Society of Automotive Engineers
Sec — Secondary
SFI — Sequential Multiport Fuel Injection
SI — System International
SIR — Supplemental Inflatable Restraint System
SOHC — Single Overhead Camshaft
Sol — Solenoid
SPEC — Specification
Speedo — Speedometer
SRS — Supplemental Restraint System
ST — Start / Scan Tool
Sw — Switch
SWB — Short Wheel Base
SYN — Synchronize 905RY00010
Tach — Tachometer
TB — Throttle Body
TBI — Throttle Body Fuel Injection
TCC — Torque Converter Clutch
TCM — Transmission Control Module
TDC — Top Dead Center
Term — Terminal
TEMP — Temperature
TOD— Torque On Demand
TP — Throttle Position
TRANS — Transmission/Transaxle
TURBO — Turbocharger
RODEO
GENERAL INFORMATION
Maintenance and Lubrication
CONTENTS
Maintenance Schedule List . . . . . . . . . . . . . . . 0B–1 Lubricant Viscosity Chart . . . . . . . . . . . . . . . . . 0B–9
Explanation of Complete Vehicle Maintenance Recommended Liquid Gasket . . . . . . . . . . . 0B–11
Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0B–5 Recommended Thread Locking Agents . . . 0B–11
Recommended Fluids and Lubricants . . . . 0B–8 Maintenance Service Data . . . . . . . . . . . . . . . . 0B–12
Maintenance Schedule List Severe Driving Conditions

If the vehicle is usually operated under any of the severe
Normal Vehicle Use driving conditions listed below, it is recommended that the
The maintenance instructions in this Maintenance applicable maintenance services be performed at the
Schedule are based on the assumption that the vehicle specified interval shown in the chart below.
will be used as designed:
Severe driving conditions:
D to carry passengers and cargo within the limitations
specified on the tire placard located on the inside of D Towing a trailer, using a camper or car top carrier.
the glove compartment door; D Repeated short trips of less than 8 Km (5 miles) with
D to be driven on reasonable road surfaces within legal outside temperature remaining below freezing.
operating limits; D Extensive idling and/or low speed driving for long
D to be driven on a daily basis, as a general rule, for at distances, such as police, taxi or door–to–door
least several miles/kilometers; delivery use.
D to be driven on unleaded fuel D Operating on dusty, rough, muddy or salt spread
Unusual or severe operating conditions will require more roads.
frequent vehicle maintenance, as specified in the
following sections.
ITEMS INTERVAL
CHANGE ENGINE OIL AND OIL FILTER Every 3,000 miles (4,800 km) or 3 months
CHANGE AUTOMATIC TRANSMISSION FLUID Every 20,000 miles (32,000 km)
CHANGE REAR AXLE OIL Every 15,000 miles (24,000 km)
REPLACE TIMING BELT Every 75,000 miles (120,000 km)
REPLACE AIR CLEANER FILTER See explanation of service, page 0B–5
CHANGE POWER STEERING FLUID Every 30,000 miles (48,000 km)
Mileage Only Items
UEROM2
Mileage/Months
UEROM3
UEROM4
Explanation of Complete Vehicle Check and adjust the valve clearance every if noise
occurs.
Maintenance Schedule
Brief explanations of the services listed in the preceding Tire Rotation
Maintenance Schedule are presented below. Rotate tires every 7,500 miles (12,000 km).
Replace all questionable parts and note any necessary
repairs as you perform these maintenance procedures. Spark Plug Wire Inspection
Front and Rear Axle Lubricant Check the spark plug wires at 60,000 mile (96,000 km)
Replacement intervals.
Check the lubricant level after every 7,500 miles (12,000
km) of operation and add lubricant to level of filler hole if Front Wheel Bearings Lubricant
necessary. Replacement
Replace the front and rear axle lubricant at 15,000 miles Clean and repack the front wheel bearings at 30,000
(24,000 km) and 30,000 miles (48,000 km) and after miles (48,000 km) intervals.
every 30,000 miles (48,000 km) of operation thereafter. Refer to DRIVE SHAFT SYSTEM (SEC. 4C).
Manual Transmission Lubricant Radiator Core and Air Conditioning

Replacement Condenser Cleaning
Check the lubricant level after every 7,500 miles (12,000 Clean the front of the radiator core and air conditioning
km) of operation and add lubricant to level of filler hole if condenser, at 60,000 miles (96,000 km) intervals.
necessary.
Replace the transmission lubricant at 15,000 miles Fluid Level Check
(24,000 km) and 30,000 miles (48,000 km) and after A fluid loss in any system (except windshield
every 30,000 miles (48,000 km) of operation thereafter. washer) may indicate a problem. Repair the system
at once.
Transfer Case Lubricant Replacement
Engine oil level
Check the lubricant level after every 7,500 miles (12,000
Check level and add if necessary. The best time to check
km) of operation and add lubricant to level of filler hole if
the engine oil level is when the oil is warm. After stopping
necessary. the engine with the vehicle on a level surface, wait a few
Replace the transfer case lubricant at 15,000 miles minutes for the oil to drain back to the oil pan. Pull out the
(24,000 km) and 30,000 miles (48,000 km) and after oil level indicator (dipstick). Wipe it clean and push the oil
every 30,000 miles (48,000 km) of operation thereafter. level indicator back down all the way. Pull out the oil level
indicator, keeping the tip down, and look at the oil level on
Air Cleaner Element Replacement it.
Replace the air cleaner under normal operating Add oil, if needed, to keep the oil level above the “ADD”
conditions every 30,000 miles (48,000 km). mark and between the “ADD” and “FULL” marks in the
Operation of the vehicle in dusty areas will necessitate operating range area. Avoid overfilling the engine since
more frequent replacement. this may cause engine damage. Push the oil level
indicator back down all the way after taking the reading.
Spark Plug Replacement If you check the oil level when the oil is cold, do not run the
Replace the plugs at 100,000 miles (160,000 km) engine first. The cold oil will not drain back to the pan fast
intervals with the type specified at the end of this section. enough to give a true oil level.
Engine coolant level and condition
Cooling System Service
Check engine coolant level in the coolant reservoir and
Drain, flush and refill system with new engine coolant.
add engine coolant if necessary. Inspect the engine
Refer to “Recommended Fluids and Lubricants” in this coolant and replace it if dirty or rusty.
section, or ENGINE COOLING (SEC.6B).
Windshield washer fluid level
Timing Belt Replacement Check washer fluid level in the reservoir and add if
Replacement of the timing belt is recommended at every necessary.
100,000 miles (160,000 km). Power steering system reservoir level
Failure to replace the timing belt may result in serious
Check and keep at the proper level.
damage to the engine.
Brake master cylinder reservoir level
Valve Clearance Adjustment (V6, 3.2L Check fluid. Keep fluid at proper level. A low fluid level can
ENG) indicate worn disc brake pads which may need to be
Incorrect valve clearance will result in increased engine serviced.
noise and reduced engine output. Hydraulic clutch system
Retorque the camshaft bracket bolts before checking and
Check fluid level in the reservoir. Add fluid as required.
adjusting the valve clearance.
Battery fluid level normal highway speeds means a wheel balancing is
Check fluid level in the battery. needed. Check tire pressure when the tires are “cold”
(include the spare).
Fluid Leak Check Maintain pressure as shown in the tire placard, which is
located on the driver’s door lock pillar.
Check for fuel, water, oil or other fluid leaks by looking at
the surface beneath the vehicle after it has been parked Steering System Operation
for a while. Water dripping from the air conditioning
system after use is normal. If you notice gasoline fumes or Be alert for any changes in steering action. An inspection
fluid at any time, locate the source and correct it at once. or service is needed when the steering wheel is harder to
turn or has too much free play, or if there are unusual
Engine Oil and Oil Filter Replacement sounds when turning or parking.
Always use API SE, SF, SG, SH or ILSAC GF–1 quality Brake Systems Operation
oils of the proper viscosity.
When choosing an oil, consider the range of Watch for the “BRAKE” light coming on. Other signs of
temperatures the car will be operated in before the next oil possible brake trouble are such things as repeated pulling
change. Then, select the recommended oil viscosity from to one side when braking, unusual sounds when braking
the chart. or between brake applications, or increased brake pedal
Always change the oil and the oil filter as soon as possible travel. If you note one of these conditions, repair the
after driving in a dust storm. system at once.
For convenience, the following should be done when
Engine Cooling System Inspection wheels are removed for rotation: Inspect lines and hoses
for proper hookup, bindings, leaks, crack, chafing etc.
Inspect the coolant/anti–freeze. If the coolant is dirty or
Inspect disc brake pads for wear and rotors for surface
rusty, drain, flush and refill with new coolant. Keep coolant
condition.
at the proper mixture for proper freeze protection,
Inspect other brake parts, including parking brake drums,
corrosion inhibitor level and best engine operating
linings etc., at the same time. Check parking brake
temperature. Inspect hoses and replace if cracked,
adjustment.
swollen or deteriorated. Tighten the hose clamps if
Inspect the brakes more often if habit or conditions
equipped with screw–type clamps. Clean outside of
result in frequent braking.
radiator and air conditioning condenser. Wash filler cap
and neck. To help ensure proper operation, a pressure Parking Brake and Transmission Park
test of both the cooling system and the cap is also
Mechanism Operation
recommended.
Park on a fairly steep hill and hold the vehicle with the
Exhaust System Inspection parking brake only. This checks holding ability. On
Visually inspect the exhaust pipes, muffler, heat shields automatic transmission vehicles, shifting from “P”
and hangers for cracks, deterioration, or damage. position to the other positions cannot be made unless the
Be alert to any changes in the sound of the exhaust brake pedal is depressed when the key switch is in the
system or any smell of fumes. These are signs the system “ON” position or the engine is running.
may be leaking or overheating. Repair the system at WARNING: BEFORE CHECKING THE STARTER
once, if these conditions exist. (See also “Engine Exhaust SAFETY SWITCH OPERATION BELOW, BE SURE TO
Gas Safety” and “Three Way Catalytic Converter” in the HAVE ENOUGH ROOM AROUND THE VEHICLE.
Owner’s manual.) THEN FIRMLY APPLY BOTH THE PARKING BRAKE
AND THE REGULAR BRAKE. DO NOT USE THE
Fuel Cap, Fuel Lines, and Fuel Tank ACCELERATOR PEDAL. IF THE ENGINE STARTS,
Inspection BE READY TO TURN OFF THE KEY PROMPTLY.
TAKE THESE PRECAUTIONS BECAUSE THE
Inspect the fuel tank, the fuel cap and the fuel lines every VEHICLE COULD MOVE WITHOUT WARNING AND
60,000 miles (96,000 km) for damage which could cause POSSIBLY CAUSE PERSONAL INJURY OR
leakage. PROPERTY DAMAGE.
Inspect the fuel cap and the gasket for correct sealing and
physical damage. Replace any damaged parts.
Starter Safety Switch Operation
Drive Belt Inspection (Automatic Transmission)
Check the serpentine belt driving for cracks, fraying, Check by trying to start the engine in each gear while
wear, and correct tension every 30,000 miles (48,000 setting the parking brake and the foot brake. The starter
km). Replace as necessary. should crank only in “P” (Park) or “N” (Neutral).
Wheel Alignment, Balance and Tires Starter Safety Switch Operation (Manual
Operation Transmission)
Uneven or abnormal tire wear, or a pull right or left on a To check, place the shift lever in “Neutral”, push the clutch
straight and level road may show the need for a wheel pedal halfway and try to start. The starter should not
alignment. A vibration of the steering wheel or seat at
crank. The starter should crank only when the clutch Accelerator Linkage Inspection
pedal is fully depressed. Inspect for interference, binding, and damaged or
missing parts. Check accelerator pedal for smooth
Accelerator Linkage Lubrication operation and even pedal effort. Replace parts as
Lubricate the accelerator pedal fulcrum pin with chassis needed.
grease.
Steering and Suspension Inspection

Inspect the front and rear suspension and steering
system for damaged, loose or missing parts or signs of
wear. Inspect power steering lines and hoses for proper
hookup, binding, leaks, cracks, chafing, etc.
Body and Chassis Lubrication

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

Check the propeller shaft flange–to–pinion bolts for
proper torque to 63 N•m (46 lb ft) for front and rear
propeller shaft.
Automatic Transmission Fluid

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

Check to see if the clearance between cruise link and
accelerator link is normal. Also check that the connected
properly.
Clutch Lines and Hoses Inspection

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

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

Note the clutch pedal free play. It should be 5 – 15 mm (0.2
– 0.6 in). Adjust clutch control when there is little or no free
play.
Recommended Fluids and Lubricants

USAGE FLUID/LUBRICANT
Engine API SE, SF, SG, SH or ILSAC GF-1 Engine oil (See oil
chart on the following page for proper viscosity)
Mixture of water and good quality ethylene glycol base
Engine coolant
type antifreeze.
Brake system DOT-3 hydraulic brake fluid.
Power steering system DEXRON -III Automatic transmission fluid.
Automatic transmission DEXRON -III Automatic transmission fluid.
MUA Type Manual transmission & Transfer case Engine oil
(See oil chart on following page for proper viscosity)
Rear axle and front axle GL-5 gear lubricant (Standard differential)
GL-5 Limited slip differential gear lubricant together
with limited slip differential lubricant additive (Part No.
8-01052-358-0) or equivalent (If equipped with optional
limited slip differential) (See oil chart in this section for
proper viscosity)
Clutch system
a. Pivot points Chassis grease
b. Clutch fork joint Chassis grease
c. Master cylinder DOT-3 hydraulic brake fluid
Hood latch assembly
a. Pivots and spring anchor Engine oil
b. Release pawl Chassis grease
Hood and door hinges Engine oil
Chassis lubrication Chassis grease
Parking brake cables Chassis grease
Front wheel bearings Multipurpose grease
Shift on the fly system GL-5 gear lubricant (SAE 75W-90)
Body door hinge pins and linkage, fuel door hinge, rear Engine oil
compartment lid hinges
Windshield washer solvent Washer fluid
Key lock cylinder Synthetic light weight engine oil (SAE 5W-30)
Accelerator linkage Chassis grease
Lubricant Viscosity Chart

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

Type Brand Name Manufacturer Remarks
Three Bond 1207B Three Bond For Engine Repairs
Three Bond 1207C Three Bond
RTV*
Three Bond 1215 Three Bond For Axle Case
Silicon Base
Three Bond 1280 Three Bond Repairs T/M
Three Bond 1281 Three Bond Repairs T/M
Water Base Three Bond 1141E Three Bond For Engine Repairs
Belco Bond 4 Isuzu
Solvent For Engine Repairs
LOCTITE 515 Loctite
Anaerobic LOCTITE 518 Loctite All
LOCTITE 17430 Loctite
* RTV: Room Temperature Vulcanizer Application Steps

NOTE: 1. Completely remove all lubricant and moisture from
1. It is very important that the liquid gaskets listed above the bolts and the female-threaded surfaces of the
or their exact equivalent be used on the vehicle. parts to be joined.
The surfaces must be perfectly dry.
2. Be careful to use the specified amount of liquid
gasket. 2. Apply LOCTITE to the bolts.
Follow the manufacturer’s instructions at all times.
3. Be absolutely sure to remove all lubricants and
moisture from the connecting surfaces before
applying the liquid gasket.
The connecting surfaces must be perfectly dry.
4. Do not apply LOCTITE 17430, LOCTITE 515 and
LOCTITE 518 between two metal surfaces having a
clearance of greater than 0.25 mm (0.01 in). Poor
adhesion will result.
Recommended Thread Locking

Agents
LOCTITE Type LOCTITE Color
LOCTITE 242 Blue
LOCTITE 262 Red
LOCTITE 271 Red F00RW014
3. Tighten the bolts to the specified torque.

After tightening, be sure to keep the bolts free from
vibration and torque for at least an hour until
LOCTITE hardens.
NOTE: When the application procedures are specified in
this manual, follow them.
Maintenance Service Data

Service Data and Specifications
ENGINE Valve clearance (cold): only V6–3.2L ENG Intake 0.28±0.05 mm (0.011±0.002 in)
Exhaust 0.3±0.05 mm (0.012±0.002 in)
Spark plug type K16PR-P11/PK16PR11/RC10PYP4
Spark plug gap 1.05 mm (0.04 in)
CLUTCH Clutch pedal free play 5-15 mm (0.20-0.59 in)
BRAKE Brake pedal free play 6-10 mm (0.24-0.39 in)
Parking brake travel 6-7 notches
WHEEL ALIGNMENT Toe-in (Front) 0±2 mm (0±0.08 in)
Toe-in (Rear) 0±5 mm (0±0.2 in)
Camber (Front) 0°±30’
Camber (Rear) 0°±1°
Caster (Front) 2° 30’±45’
Toe–Axis (Rear) ±1°
PROPELLER SHAFT Flange torque 63 N·m (46 lb ft)
WHEEL AND TIRES Size P225/75R15 P245/70R16
Wheel nut torque 118 N·m (87 lb ft)
Tire inflation pressure (Front) 200 kPa (29 psi) 180 kPa (26 psi)
* Tire inflation pressure (Rear) 200 kPa (29 psi) 180 kPa (26 psi)
* Unless otherwise specified on tire information label on the vehicle.
Approximate Capacities
Items Metric Measure U.S. Measure
Fuel tank 80 L 21.1 Gal.
* Crankcase (V6–3.2L ENGINE) Oil Change with Filter 4.7 L 5.0 Qt
* Crankcase (L4–2.2L ENGINE) Oil Change with Filter 4.5 L 4.8 Qt
Coolant M/T (V6–3.2L ENG) 11.0 L 11.6 Qt
M/T (L4–2.2L ENG) 6.9 L 7.3 Qt
A/T 11.1 L 11.7 Qt
Transmission Manual 2.95 L 3.1 Qt
Automatic 8.6 L 9.1 Qt
Transfer 1.45 L 1.5 Qt
Axle Rear 1.77 L 1.87 Qt
Front V6-3.2L ENG 1.25 L 1.33 Qt
L4-2.2L ENG 1.05 L 1.10 Qt
Shift on the fly system 0.12 L 0.13 Qt
Power steering 1.0 L 1.1 Qt
Air conditioning (R-134a) 0.6 L 1.32 Qt
*Crankcase capacities shown are approximate refill capacities. After refill, recheck oil level.
RODEO
HEATING, VENTILATION AND AIR

CONDITIONING (HVAC)
HVAC SYSTEMS
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 1A–2 Control Lever Assembly and / or Control
Heating and Ventilation System . . . . . . . . . . . 1A–2 Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–23
General Description . . . . . . . . . . . . . . . . . . . . 1A–2 Control Lever Assembly, Control Cable
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . 1A–6 and Associated Parts . . . . . . . . . . . . . . . . . . 1A–23
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–24
Individual Inspection . . . . . . . . . . . . . . . . . . . 1A–11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–25
Heater Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–13 Control Panel Illumination Bulb . . . . . . . . . . . . 1A–26
Heater Unit and Associated Parts . . . . . . . . 1A–13 Control Panel Illumination Bulb and
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–26
Heater Core and / or Mode Door . . . . . . . . . . 1A–14
Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–26
Resistor and Associated Parts . . . . . . . . . . 1A–26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–26
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–15
Air Conditioning System . . . . . . . . . . . . . . . . . . 1A–27
Heater Mode Control Link Unit . . . . . . . . . . . . 1A–16
General Description . . . . . . . . . . . . . . . . . . . . 1A–27
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–37
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–16
Air Source Select Lever Diagnosis . . . . . . . 1A–47
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–17
Individual Inspection . . . . . . . . . . . . . . . . . . . 1A–50
Heater Temperature Control Link Unit . . . . . . 1A–17
General Repair Procedure . . . . . . . . . . . . . . 1A–51
Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–53
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–17
Compressor Assembly . . . . . . . . . . . . . . . . . . . 1A–58
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–18
Compressor Assembly and Associated
Blower Assembly . . . . . . . . . . . . . . . . . . . . . . . . 1A–18 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–58
Blower Assembly and Associated Parts . . 1A–18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–58
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–19 New Compressor Installation . . . . . . . . . . . . 1A–59
Blower Link Unit and / or Mode door . . . . . . . 1A–19 Condenser Assembly . . . . . . . . . . . . . . . . . . . . 1A–60
Disassembled View . . . . . . . . . . . . . . . . . . . . 1A–19 Condenser Assembly and Associated Parts 1A–60
Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–21 Condenser Fan Motor . . . . . . . . . . . . . . . . . . . . 1A–61
Blower Motor and Associated Parts . . . . . . 1A–21 Condenser Fan Motor and Associated Parts 1A–61
Rear Heater Duct, Defroster Nozzle and Receiver / Drier . . . . . . . . . . . . . . . . . . . . . . . . . 1A–62
Ventilation Duct . . . . . . . . . . . . . . . . . . . . . . . . . 1A–22
Receiver / Drier and Associated Parts . . . . 1A–62
Rear Heater Duct, Defroster Nozzle,
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–62
Ventilation Duct and Associated Parts . . . 1A–22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–62
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–23 Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . 1A–63
Pressure Switch and Associated Parts . . . 1A–63
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–63 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–72
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–63 Magnetic Clutch Assembly (DKV-14G Type) 1A–73
Evaporator Assembly . . . . . . . . . . . . . . . . . . . . 1A–64 Parts Location View . . . . . . . . . . . . . . . . . . . . 1A–73
Evaporator Assembly and Associated Parts 1A–64 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–73
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–64 Inspection and Repair . . . . . . . . . . . . . . . . . . 1A–75
Electronic Thermostat, Evaporator Core Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . 1A–77
and/or Expansion Valve . . . . . . . . . . . . . . . . . 1A–65 Oil Specification . . . . . . . . . . . . . . . . . . . . . . . 1A–77
Disassembled View . . . . . . . . . . . . . . . . . . . . 1A–65 Handling of Oil . . . . . . . . . . . . . . . . . . . . . . . . 1A–77
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–66 Compressor Oil Check . . . . . . . . . . . . . . . . . 1A–77
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–66 Checking and Adjusting Oil Quantity for
Refrigerant Line . . . . . . . . . . . . . . . . . . . . . . . . . 1A–67 Used Compressor . . . . . . . . . . . . . . . . . . . . . 1A–77
Refrigerant Line and Associated Parts . . . . 1A–67 Checking and Adjusting for Compressor
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–68 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 1A–78
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–68 Contamination of Compressor Oil . . . . . . . . 1A–78
Main Data And Specifications . . . . . . . . . . . . . 1A–68 Oil Return Operation . . . . . . . . . . . . . . . . . . . 1A–78
Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–71 Replacement of Component Parts . . . . . . . 1A–78
Service Precaution . . . . . . . . . . . . . . . . . . . . 1A–71 Main Data and Specifications . . . . . . . . . . . . . 1A–79
General Description . . . . . . . . . . . . . . . . . . . . . . 1A–71 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A–81

systems.
Heating and Ventilation System
General Description
Heater
When the engine is warming up, the warmed engine The air selector knob, with its different modes, also allows
coolant is sent out into the heater core. The heater system you to select and maintain the most comfortable
supplies warm air into the passenger compartment to passenger compartment temperature.
warm it up. The air source select lever is used to select either
Outside air is circulated through the heater core of the “FRESH” for the introduction of the outside air, or “CIRC”
heater unit and then back into the passenger for the circulation of the inside air. When the lever is set to
compartment. By controlling the mixture of outside air and “FRESH”, the outside air is always taken into the
heater core air, the most comfortable passenger passenger compartment. When setting the lever to
compartment temperature can be selected and “CIRC” position, the circulation of air is restricted only to
maintained. the inside air with no introduction of the outside air and the
The temperature of warm air sent to the passenger air in the passenger compartment gets warm quickly.
compartment is controlled by the temperature control However, the lever is normally set to “FRESH” to prevent
knob. This knob acts to open and close the air mix door, the windshield from clouding.
thus controlling the amount of air passed through the
heater core.
840RY00032
Legend (5) Duct (W/O A/C)

(1) Defroster Nozzle (6) Heater Unit
(2) Ventilation Duct (7) Ventilation Lower Duct
(3) Blower Assembly (8) Rear Heater Duct
(4) Evaporator Assembly (With A/C)
Control Lever Assembly
The control lever assembly has some cables to control The fan control is used to control the amount of air sent
the mode and temperature of the heater unit and the out by the resistor at four levels from “LOW” to “HIGH”.
mode door for the air source of the blower assembly.
865RW006
Legend (4) Air Conditioning (A/C) Switch (W/ A/C)

(1) Air Source Select Lever (5) Temperature Control Knob
(2) Air Select Knob (6) Middle Position
(3) Fan Control Lever (Fan Switch)
Ventilation 4. Def/Foot – In this position, air flow is delivered to the

Setting the air source select lever to “FRESH” position foot, while sending approx. 40% of total amount of air
to the windshield.
allows the heating system to work with sending the fresh
air from outside. Selecting this mode allows air conditioning system to
The blower fan also serves to deliver fresh outside air to work while the fan switch is turned to on position, even
if the A/C switch is off.
the passenger compartment to assure adequate
ventilation. Also the fresh air can be delivered even when the circ
position is selected.
Air Select Knob
5. Defrost – In this position, most of the air is delivered
The air select knob allows you to direct heated air into the to the windshield and a small amount is delivered to
passenger compartment through different outlets. the side windows.
1. Vent – In this position, air is discharged from the Selecting this mode allows air conditioning system to
upper air outlet. Air quantity is controlled by the fan work while the fan switch is turned to on position, even
control lever. if the A/C switch is off.
2. Bi-Level – In this position, air flow is divided between Also the fresh air can be delivered even when the circ
the upper air outlets and the floor air outlets, with position is selected.
warmer air delivered to the floor outlets than the air
Moving the air source select lever to the “CIRC” position
delivered to the upper air outlets when the temp lever
is in middle position. provides quickest heat delivery by closing the blower
assembly mode door. In this position, outside air is not
3. Foot – In this position, air flow is delivered to the foot, delivered to the passenger compartment.
while sending a small amount of air to the windshield.
C01RW001
Air Source Select Lever Temperature Control Knob

The intake of outside air and the circulation of inside air When the temperature control knob is in the “COLD”
are controlled by sliding this lever left or right. position, the air mix door closes to block the flow air to the
And even though the circ position is selected, the fresh air heater core.
can be delivered while the DEF or DEF/FOOT position is When the temperature control knob is in the “HOT”
selected. position, the air mix door opens to allow air to pass
through the heater core and heat the passenger
Fan Control Lever compartment.
This lever controls the blower motor speed to regulate the Placing the knob in a intermediate position will cause a
amount of air delivered to the defrost, foot, and ventilation lesser or greater amount air to reach the heater core. In
ducts: this mode the passenger compartment temperature can
1. Low be regulated.
2. Medium Low
3. Medium High
4. High
Wiring Diagram
D08RY00545
Diagnosis
Heating Cycle diagnosis
No heating or insufficient heating. Blower motor does not run or runs Refer to “FAN CONTROL LEVER
improperly. (FAN SWITCH) DIAGNOSIS”.
Engine coolant temperature is low. Check the engine coolant
temperature after warming up the
engine and check the thermostat.
Replace as necessary.
Insufficient engine coolant. Add engine coolant as required.
Circulation volume of engine coolant Check if the water hose to the heater
is insufficient. core is clogged, collapsed or twisted.
Repair or replace as necessary.
Heater core clogged or collapsed. Clean or replace as necessary.
The heater cores is not provided with Repair the temperature control link
air sent from the blower motor. unit or mode doors.
Duct connections defective or Repair or replace as necessary.
unsealing.
Control lever moves but mode door Cable attaching clip is not correct. Repair
does not operate.
operate
Link unit of heater or blower Repair
assembly defective.
The intake actuator is inoperative. Refer to “AIR SOURCE SELECT
LEVER DIAGNOSIS”
The mode door cannot be set to the Link unit of heater unit. Repair.
mode selected.
selected
Control cable is not adjusted. Adjust.
Fan Control Lever (Fan Switch) Diagnosis
Current flows to the blower motor through the heater relay
(X-1) to activate the rotation of the blower motor by
turning “ON” the fan control knob (fan switch). Blower
motor speed is controlled in stages by the resistor, by
operating the switch from “LOW” to “HIGH”.
For the inspection of the relays, switches and units in
each table, refer to “INDIVIDUAL INSPECTION” in this
section.
D08RY00546

Blower motor does not run. — Refer to Chart A
Blower motor does not run in certain — Refer to Chart B, C, D and E
position (s).
Blower motor does not stop at “OFF” — Refer to Chart F
position.
Chart “A” Blower Motor Does Not Run

Step Action Yes No
1 Is relay (X-1) OK? Go to Step 2 Replace
2 Is fuse EB-5 (15A) OK? Go to Step 3 Replace
3 Is fuse EB-6 (15A) OK? Go to Step 4 Replace
5 Is fan control lever OK? Replace control
Go to Step 6 lever assembly.
6 Is blower motor OK? Go to Step 7 Replace
7 1. Turn the ignition switch “ON”. Poor ground or
2. Turn fan control lever “ON”. open circuit either
3. Check to see if battery voltage is present at chassis side between chassis
connector terminal No. C38-1 side connector
terminal
No. C38-2 and Open circuit
No. C41-2 or between No.
No. I23-1 and EB-5 (15A) /
body ground EB-6 (15A) fuse
(No. B-7). and No. C38-1.
Chart “B” Blower Motor Does Not Run At Low Position

Step Action Yes No
2 Is fan control lever (Fan Switch) OK? Open circuit
between chassis
side connector
terminal
No. C41-1 and Replace control
No.I23-2. lever assembly.
Chart “C” Blower Motor Does Not Run At Medium Low Position
Step Action Yes No
between the
chassis side
connector
terminal
No. I23-3. lever assembly.
Chart “D” Blower Motor Does Not Run At Medium High Position
Step Action Yes No
between chassis
side connector
terminal
Chart “E” Blower Motor Does Not Run At High Position

Step Action Yes No
between Chassis
side connector
terminal
Chart “F” Blower Motor Does Not Stop In The “OFF” Position
Step Action Yes No
1 Is the fan control lever (Fan Switch) OK? Short circuit
between chassis
side connector
terminal
No. C38-2 and
No. C41-2,
No. C41-3 and
No. I23-5,
No. C41-6 and
No. I23-4,
No. C41-4 and
No. I23-3 or
No. I23-2 lever assembly.
Individual Inspection Fan Control Lever (Fan Switch)

Blower Motor 1. Check for continuity between the terminals of the fan
switch.
1. Disconnect the blower motor (C-38) connector from
the blower motor.
2. Connect the battery positive terminal to the No. 1
terminal of the blower motor and the negative to the
No. 2.
3. Be sure to check to see if the blower motor operates
correctly.
D08RW058
Heater Relay
1. Disconnect the heater relay (X-1).
D When removing the connector for relay, unfasten
the tank lock of the connector by using a
screwdriver, then pull the relay (1) out.
873RS005
Resistor
1. Disconnect the resistor (C-41) connector.
2. Check for continuity and resistance between the
terminals of the resistor.
825RS001
840RS001
2. Check for continuity between the heater relay (X-1)
terminals.
825RS179
Heater Unit
Heater Unit and Associated Parts
840RY00033
Legend (6) Evaporator Assembly (A/C only)

(1) Instrument Panel Assembly (7) Duct
(2) Cross Beam Assembly (8) Heater Unit Assembly
(3) Instrument Panel Bracket (9) Heater Hose
(4) Ventilation Lower Duct (10) Resistor Connector
(5) Rear Heater Duct
Removal 7. Disconnect resistor connector.

8. Remove duct.
conditioning). 10. Remove ventilation lower duct.
D Refer to Refrigerant Recovery in this section. 11. Remove rear heater duct.
4. Remove the Instrument panel assembly. D Remove foot rest, carpet and 3 clips.
D Refer to Instrument Panel Assembly in Body and 12. Remove heater unit assembly.
Accessories section. D Disconnect heater hoses at heater unit.
5. Remove instrument panel bracket.
6. Cross Beam Assembly.
Installation 2. Adjust the control cables.

To install, follow the removal steps in the reverse order, D Refer to Control Lever Assembly in this section.
noting the following points: 3. When installing the heater unit, defroster nozzle and
1. When handling the PCM and the control unit, be center vent duct, be sure that the proper seal is made,
careful not to make any improper connection of the without any gap between them.
connectors.
Heater Core and / or Mode Door

Disassembled View
860RW001
Legend (4) Mode Door

(1) Heater Core (5) Duct
(2) Case (Temperature Control) (6) Case (Mode Control)
(3) Heater Unit
Removal 3. Discharge and recover refrigerant (with air

conditioning).
1. Disconnect the battery ground cable. D Refer to Refrigerant Recovery in this section.
4. Remove heater unit. 9. Pull out the mode door while raising up the catch of
D Refer to Heater Unit in this section. the door lever.
5. Remove duct.
6. Remove case (Mode control) and do not remove link
unit at this step.
7. Remove case (Temperature control) separate two
halves of core case.
860RS004
Inspection
Check for foreign matter in the heater core, stain or the
core fin defacement.
860RS002
8. Remove heater core (1). Installation

1. Check that each mode door operates properly.
860RS003
Heater Mode Control Link Unit

Disassembled View
860RW002
Legend (4) Clip

(1) Case (Mode Control) (5) Door Lever
(2) Heater Unit (6) Rod
(3) Mode Sub-lever (7) Washer and Mode Main Lever
Removal
conditioning)
5. Remove the case (Mode control) from heater unit.
6. Remove washer and the mode main lever.
7. Remove rod.
8. Press the tab of the sub-lever inward, and take out the
sub-lever.
860RS006
9. Pull out the door lever while raising up the catch of the Installation
door lever.
To install, follow the remove steps in the reverse order,
10. Remove clip. noting the following points:
1. Apply grease to the mode sub-lever and to the
abrasive surface of the heater unit.
2. After installing the link unit, check to see if the link unit
operates correctly.
Heater Temperature Control Link Unit

Disassembled View
860RS007
Legend (4) Clip

(1) Case (Temperature control) (5) Heater Unit
(2) Clip (6) Rod
(3) Door Lever (7) Sub-lever
Removal 5. Remove the case (Temperature control) from the

heater unit.
1. Disconnect the battery ground cable. 6. Remove rod.
2. Drain engine coolant. 7. Remove sub-lever.
3. Discharge and recover refrigerant (with air 8. Pull out the door lever while raising up the catch of the
conditioning). door lever.
D Refer to Refrigerant Recovery in this section. 9. Remove clip.
Installation 2. After installing the link unit, check to see if the link unit
operates correctly.
1. Apply grease to the sub-lever and to the abrasive
surface of the heater unit.
Blower Assembly
Blower Assembly and Associated Parts
873RY00006
Legend (3) Evaporator Assembly (A/C only)

(1) Instrument Panel Assembly (4) Duct
(2) Blower Assembly (5) Heater Unit
Removal 3. Remove instrument panel assembly.

2. Discharge and recover refrigerant (with air 4. Disconnect resistor connector.
conditioning).
5. Remove duct.
6. Remove evaporator assembly (A/C only). Installation
D Refer to Evaporator Assembly in this section. To install, follow the removal steps in the reverse order.
7. Disconnect blower motor connector.
8. Remove blower assembly.
Blower Link Unit and / or Mode door

Disassembled View
873RY00007
Legend (4) Lower Case

(1) Blower Assembly (5) Intake Actuator
(2) Upper Case (6) Sub Lever
(3) Mode Door (7) Door Lever
Removal 3. Remove blower assembly.

D Refer to Blower Assembly in this section.
4. Remove intake actuator.
conditioning). 5. Remove lower case.
6. Separate the upper case and slit the lining parting
face with a knife.
873RS002
7. Pull out the mode door while raising up the catch of

door lever.
9. Remove door lever.
Installation
1. Apply grease to the door lever and to the abrasive
surface of the upper case.
2. Apply an adhesive to the parting face of the lining
when assembling the upper case.
Blower Motor
Blower Motor and Associated Parts
873RS004
Legend (4) Fan

(1) Blower Motor Connector (5) Blower Motor
(2) Blower Motor Assembly (6) Attaching Screw
(3) Clip
2. Remove blower motor connector.
4. Remove blower motor assembly.
5. Remove clip.
6. Remove fan.
7. Remove blower motor.
Rear Heater Duct, Defroster Nozzle and Ventilation Duct

Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts
840RY00031
Legend (4) Instrument Panel Bracket

(1) Defroster Nozzle (5) Instrument Panel Assembly
(2) Cross Beam Assembly (6) Rear Heater Duct
(3) Center Ventilation Duct and Side Defroster (7) Ventilation Lower Duct
Duct
Removal 4. Remove instrument panel brackets.

2. Remove instrument panel assembly. 5. Remove cross beam assembly.
D Refer to Instrument Panel Assembly in Body and D Refer to Cross Beam Assembly in Body and
Accessories section. Accessories section.
3. Remove center ventilation duct and side defroster 6. Remove ventilation lower duct.
duct.
D Remove 5 screws.
D Remove foot rest carpet and 3 clips.
8. Remove defroster nozzle.
Installation
1. Connect each duct and nozzle securely leaving no
clearance between them and making no improper
matching.
Control Lever Assembly and / or Control Cable

Control Lever Assembly, Control Cable and Associated Parts
865RY00014
Legend (4) Glove Box

(1) Control Cable (5) Instrument Panel Driver Lower Cover
(2) Control Lever Assembly Assembly
(3) Meter Cluster Assembly (6) Fan Switch Air Conditioning Switch Connector
Removal
2. Remove instrument panel driver lower cover
assembly.
3. Remove meter cluster assembly.
5. Remove the control lever attaching screws.
6. Pull the control lever assembly out and disconnect the
fan switch and air conditioning switch connectors.
865RY00015
7. Remove control level assembly.

8. Disconnect control cables at each unit side.
865RY00016
Installation
1. Adjust the control cable.
865RY00017
D Temperature control cable.

1. Turn the control knob to the left (“MAX COLD”
position).
2. Connect the control cable at the “COLD”
position of the temperature control link of the
heater unit and secure it with the clip.
D Air select control cable
1. Turn the control knob to the right (“DEFROST”
position).
2. Connect the control cable at the “DEFROST”
position of the mode control link of the heater
unit and secure it with the clip.
2. Check the control cable operation.
Control Panel Illumination Bulb

Control Panel Illumination Bulb and Removal
Associated Parts 1. Disconnect the battery ground cable.
3. Pull out the bulb socket from the panel by turning it
counterclockwise.
4. Pull the illumination bulb from the socket.
Installation
865RY00018
Legend
(1) Control Lever Assembly
(2) Bulb Socket
(3) Illumination Bulb
Resistor
Resistor and Associated Parts Removal
3. Remove resistor connector.
4. Remove duct (heater only).
5. Remove resistor.
Installation
840RW001
Legend
(1) Duct (Heater only)
(2) Resistor
(3) Resistor Connector
(4) Glove Box
Air Conditioning System
General Description
Air Conditioning Refrigerant Cycle Construction
C01RY00013
Legend (9) Condenser

(1) Electronic Thermostat (10) Compressor
(2) Evaporator Core (11) Magnetic Clutch
(3) Evaporator Assembly (12) Mode (HEAT) Control Door
(4) Temperature Sensor (13) Temp. Control Door (Air Mix Door)
(5) Blower Motor (14) Heater Core
(6) Expansion Valve (15) Mode (VENT) Control Door
(7) Pressure Switch or Pressure Sensor (16) Heater Unit
(8) Receiver/Drier (17) Mode (DEF) Control Door
The refrigeration cycle includes the following four Evaporation

processes as the refrigerant changes repeatedly from The refrigerant is changed from a liquid to a gas inside the
liquid to gas and back to liquid while circulating. evaporator. The refrigerant mist that enters the
evaporator vaporizes readily. The liquid refrigerant This vehicle is equipped with a five-vane rotary
removes the required quantity of heat (latent heat of compressor.
vaporization) from the air around the evaporator core The specified amount of the compressor oil is 150cc
cooling fins and rapidly vaporizes. Removing the heat (5.0 fl. oz.).
cools the air, which is then radiated from the fins and The oil used in the HFC-134a system compressor differs
lowers the temperature of the air inside the vehicle. from that used in R-12 systems.
The refrigerant liquid sent from the expansion valve and Also, compressor oil to be used varies according to the
the vaporized refrigerant gas are both present inside the compressor model. Be sure to avoid mixing two or more
evaporator as the liquid is converted to gas. different types of oil.
With this change from liquid to gas, the pressure inside If the wrong oil is used, lubrication will be poor and the
the evaporator must be kept low enough for vaporization compressor will seize or malfunction.
to occur at a lower temperature. Because of that, the The magnetic clutch connector is a waterproof type.
vaporized refrigerant is sucked into the compressor.
Magnetic Clutch
Compression The compressor is driven by the drive belt from the crank
The refrigerant is compressed by the compressor until it is pulley of the engine. If the compressor is activated each
easily liquefied at normal temperature. time the engine is started, this causes too much load to
The vaporized refrigerant in the evaporator is sucked into the engine. The magnetic clutch transmits the power from
the compressor. This action maintains the refrigerant the engine to the compressor and activates it when the air
inside the evaporator at a low pressure so that it can conditioning is ON. Also, it cuts off the power from the
easily vaporize, even at low temperatures close to 0°C engine to the compressor when the air conditioning is
(32°F). OFF. Refer to Compressor in this section for magnetic
Also, the refrigerant sucked into the compressor is clutch repair procedure.
compressed inside the cylinder to increase the pressure
and temperature to values such that the refrigerant can
easily liquefy at normal ambient temperatures.
Condensation
The refrigerant inside the condenser is cooled by the
outside air and changes from gas to liquid.
The high temperature, high pressure gas coming from the
compressor is cooled and liquefied by the condenser with
outside air and accumulated in the receiver/drier. The
heat radiated to the outside air by the high temperature,
high pressure gas in the compressor is called heat of
condensation. This is the total quantity of heat (heat of
vaporization) the refrigerant removes from the vehicle
interior via the evaporator and the work (calculated as the
quantity of heat) performed for compression.
Expansion
The expansion valve lowers the pressure of the
refrigerant liquid so that it can easily vaporize. 871RX026
The process of lowering the pressure to encourage Legend

vaporization before the liquefied refrigerant is sent to the (1) Magnetic Clutch
evaporator is called expansion. In addition, the expansion (2) Magnetic Clutch Connector
valve controls the flow rate of the refrigerant liquid while (3) Compressor
decreasing the pressure.
That is, the quantity of refrigerant liquid vaporized inside
the evaporator is determined by the quantity of heat which Condenser
must be removed at a prescribed vaporization The condenser assembly is located in front of the radiator.
temperature. It is important that the quantity of refrigerant It provides rapid heat transfer from the refrigerant to the
be controlled to exactly the right value. cooling fins.
Also, it functions to cool and liquefy the high-pressure and
Compressor high-temperature vapor sent from the compressor by the
The compressor performs two main functions: radiator fan or outside air.
It compresses low-pressure and low-temperature A condenser may malfunction in two ways: it may leak, or
refrigerant vapor from the evaporator into high-pressure it may be restricted. A condenser restriction will result in
and high-temperature refrigerant vapor to the condenser. excessive compressor discharge pressure. If a partial
It pumps refrigerant and refrigerant oil through the air restriction is present, the refrigerant expands after
conditioning system. passing through the restriction.
Thus, ice or frost may form immediately after the The receiver/drier of this vehicle is made of aluminum
restriction. If air flow through the condenser or radiator is with a smaller tank. It has a 300cc refrigerant capacity.
blocked, high discharge pressures will result. During The refrigerant line connection has a bolt at the block
normal condenser operation, the refrigerant outlet line will joint, for easy servicing.
be slightly cooler than the inlet line.
The vehicle is equipped with the parallel flow type Dual Pressure Switch (V6,M/T)
condenser. A larger thermal transmission area on the The pressure switch (Dual pressure switch) is installed on
inner surface of the tube allows the radiant heat to the upper part of the receiver/drier, to detect excessively
increase and the ventilation resistance to decrease. high pressure (high pressure switch) and prevent
The refrigerant line connection has a bolt at the block compressor seizure due to the refrigerant leaking (low
joint, for easy servicing. pressure switch), so that the compressor is able to be
turned “ON” or “OFF”.
ON OFF
Compressor
(kPa/psi) (kPa/psi)
Low-pressure 205.9±29.4 176.5±19.6
control (29.9±4.3) (25.6±2.8)
High-pressure 2059.4±196.1 2942.0±196.1
control (341.3±28.4) (426.6±28.4)

Triple pressure switch is installed on the upper part of the
receiver/drier. This switch is constructed with a unitized
type of two switches. One of them is a low and high
pressure switch (Dual pressure switch) to switch “ON” or
“OFF” the magnetic clutch as a result of irregularly
high–pressure or low pressure of the refrigerant. The
other one is a medium pressure switch (Cycling switch) to
875RX003
switch “ON” or “OFF” the condenser fan sensing the
condenser high side pressure.
Legend
(1) Pressure Switch ON OFF
Compressor
(2) Receiver Drier (kPa/psi) (kPa/psi)
(3) Condenser & Receiver Tank Assembly Low-pressure 186.3±29.4 176.5±24.5
(4) Condenser Fan (6VD1 A/T) control (27.0±4.3) (25.6±3.6)
High-pressure 2353.6±196.1 2942.0±196.1
control (341.3±28.4) (426.6±28.4)
Receiver / Drier
The receiver/drier performs four functions:
D As the quantity of refrigerant circulated varies Condenser fan
ON OFF
depending on the refrigeration cycle conditions, (kPa/psi) (kPa/psi)
sufficient refrigerant is stored for the refrigeration Medium-pressure 1471.0±98.1 1078.7±117.7
cycle to operate smoothly in accordance with control (213.3±14.2) (156.4±17.1)
fluctuations in the quantity circulated.
D The liquefied refrigerant from the condenser is mixed
with refrigerant gas containing air bubbles. If Pressure Sensor
refrigerant containing air bubbles. If refrigerant
The pressure sensor is installed on the upper part of the
containing air bubbles is sent to the expansion valve,
receiver/drier. This sensor converts high pressure
the cooling capacity will decrease considerably.
Therefore, the liquid and air bubbles are separated detection of refrigerant to an electrical voltage signal and
and only the liquid is sent to the expansion valve. supplies it to the ECM. The ECM controls switching
compressor idle speed and cooling fan operation by the
D The receiver/drier utilizes a filter and drier to remove
electrical voltage signal.
the dirt and water mixed in the cycling refrigerant.
D The sight glass, installed atop the receiver/drier,
show the state of the refrigerant.
A receiver/drier may fail due to a restriction inside the
body of the unit. A restriction at the inlet to the
receiver/drier will cause high pressure.
Outlet restrictions will be indicated by low pressure and
little or no cooling. An excessively cold receiver/drier
outlet may indicate a restriction.
875RY00015 874RY00019
Legend Legend
(1) Pressure Switch (1) Expansion Valve
(2) Receiver Drier (2) Evaporator Assembly
Expansion Valve Evaporator

This expansion valve is an external pressure type and it is The evaporator cools and dehumidifies the air before the
installed at the evaporator intake port. air enters the passenger compartment. High-pressure
The expansion valve converts the high pressure liquid liquid refrigerant flows through the expansion valve into
refrigerant sent from the receiver/drier to a low pressure the low-pressure area of the evaporator. The heat in the
liquid refrigerant by forcing it through a tiny port before air passing through the evaporator core is lost to the
sending it to the evaporator. cooler surface of the core, thereby cooling the air.
This type of expansion valve consists of a temperature As heat is lost between the air and the evaporator core
sensor, diaphragm, ball valve, ball seat, spring surface, moisture in the vehicle condenses on the outside
adjustment screw, etc. surface of the evaporator core and is drained off as water.
The temperature sensor contacts the evaporator outlet When the evaporator malfunctions, the trouble will show
pipe, and converts changes in temperature to pressure. It up as an inadequate supply of cool air. The cause is
then transmits these to the top chamber of the typically a partially plugged core due to dirt, or a
diaphragm. malfunctioning blower motor.
The refrigerant pressure is transmitted to the diaphragm’s The evaporator core with a laminate louver fin is a
bottom chamber through the external equalizing pressure single-sided tank type where only one tank is provided
tube. under the core.
The ball valve is connected to the diaphragm. The
opening angle of the expansion valve is determined by
the force acting on the diaphragm and the spring
pressure.
The expansion valve regulates the flow rate of the
refrigerant. Accordingly, when a malfunction occurs to
this expansion valve, both discharge and suction
pressure get low, resulting in insufficient cooling capacity
of the evaporator.
The calibration has been changed to match the
characteristics of HFC-134a.
874RY00015
Legend
(1) Evaporator Core
(2) Expansion Valve
Electronic Thermostat
The thermostat consists of the duct sensor and
thermostat unit which functions electrically to reduce the
noises being generated while the system is in operation.
The electronic duct sensor is mounted at the evaporator 874RY00018
core outlet and senses the surface temperature of the

Legend
evaporator core. Temperature signals are input to the
thermostat unit. This information is compared by the (1) Duct Sensor
thermo unit and results in the output to operate the A/C (2) Evaporator Core
thermostat relay and turn the magnetic clutch ON or OFF (3) Thermostat Unit
to prevent evaporator freeze-up.
A characteristic of the sensor is that the resistance
decreases as the temperature increases and the
resistance increases as the temperature decreases.
Refrigerant Line
Restriction in the refrigerant line will be indicated by:
1. Suction line — A restricted suction line will cause low
suction pressure at the compressor, low discharge
pressure and little or no cooling.
2. Discharge line — A restriction in the discharge line
generally will cause the discharge line to leak.
3. Liquid line — A liquid line restriction will be evidenced
by low discharge and suction pressure and
insufficient cooling.
Refrigerant flexible hoses that have a low permeability to
refrigerant and moisture are used. These low
permeability hoses have a special nylon layer on the
inside.
852RS001
Legend
(1) Reinforcement Layer (Polyester)
(2) External Rubber Layer
(3) Internal Rubber Layer
(4) Resin Layer (Nylon)
852RY00017
Legend (5) Receiver/Drier

(1) Liquid Line (High-Pressure Pipe) (6) Condenser Assembly
(2) Clip (7) Compressor
(3) Discharge Line (High-Pressure Hose) (8) Suction Line (Low-Pressure Hose)
(4) Pressure Switch (9) Evaporator Assembly
Wiring Diagram
D08RY00540
D08RY00542
D08RY00541
Diagnosis
Air Conditioning Cycle Diagnosis
No cooling or insufficient cooling. Magnetic clutch does not run. Refer to “Magnetic Clutch Diagnosis”
in this section.
Compressor is not rotating properly. Adjust the drive belt to the specified
Drive belt is loosened or broken. tension or replace the drive belt.
Compressor is not rotating properly. Clean the magnetic clutch face or
Magnetic clutch face is not clean and replace.
slips.
Compressor is not rotating properly. Adjust the clearance. Refer to
Incorrect clearance between Compressor in this section.
magnetic drive plate and pulley.
Compressor oil leaks from the shaft
seal or shell.
Compressor is seized.
Insufficient or excessive charge of Discharge and recover the
refrigerant. refrigerant. Recharge to the
specified amount.
Leaks in the refrigerant system. Check the refrigerant system for
leaks and repair as necessary.
Discharge and recover the
refrigerant. Recharge to the
specified amount.
Condenser is clogged or insufficient Clean the condenser or replace as
radiation. necessary.
Temperature control link unit of the Repair the link unit.
heat unit is defective.
Unsteady operation due to a foreign Replace the expansion valve.
substance in the expansion valve.
Poor operation of the electronic Check the electronic thermostat and
thermostat. replace as necessary.
Insufficient velocity of cooling air. Evaporator clogged or frosted. Check the evaporator core and
replace or clean the core.
Air leaking from the cooling unit or air Check the evaporator and duct
duct. connection, then repair as
necessary.
Blower motor does not rotate Refer to Fan Control Lever (Fan
properly. Switch) Diagnosis in this section.
*For the execution of the charging and discharging
operation in the table above, refer to Recovery,
Recycling, Evacuating and Charging in this section.
Checking The Refrigerant System With Manifold Gauge
Since Refrigerant-134a (HFC-134a) is used in the air
conditioning system in this vehicle, be sure to use
manifold gauges, charging hoses and other air
conditioning service tools for HFC-134a when
checking the refrigerant system.
Conditions:
D Run the engine at Idling
D Air conditioning switch is “ON”
D Run the blower motor at “HIGH” position
D Temperature control lever set to “MAX COLD”
D Air source selector lever at “CIRC”
D Open the engine hood
D Close all the doors
Normal Pressure:
D At ambient temperature: approx. 25–30°C
(77–86°F).
D At low-pressure side: approx. 147.1–294.2 kPa
(21.3–42.7 psi).
D At high-pressure side: approx. 1372.9–1863.3 kPa
(199.1–270.2 psi).
Refer to the table on the refrigerant pressure-temperature
relationship.
HFC-134a Pressure-Temperature Relationship
Pressure Temperature
(kPa) (psi) (°C) (°F)
36 5.3 –20 –4.4
67 9.7 –15 5
104 15 –10 14
147 21 –5 23
196 28 0 32
255 37 5 41
314 45 10 50
392 57 15 59
471 68 20 68
569 82 25 77
677 98 30 86
785 114 35 95
912 132 40 104
1059 154 45 113
1216 176 50 122
Connect The Manifold Gauge
Low-pressure hose (LOW) — Suction side
High pressure hose (HI) — Discharge side
901RS180
Legend
(1) Low Side
(2) High Side

Discharge (High Gauge) Pressure Condenser clogged or dirty. Clean the condenser fins
Abnormally High
Cooling fan does not operate Check the cooling fan operation.
properly.
Discharge (High Gauge) Pressure Excessive refrigerant in system. Discharge and recover refrigerant.
Insufficient cooling.
Discharge (High Gauge) Pressure Air in system. Evacuate and charge refrigerant
Abnormally High. system.
High pressure gauge drop. (After
stopping A/C, the pressure drops
approx. 196 kPa (28 psi) quickly)
Discharge (High Gauge) Pressure Insufficient refrigerant in system. Check for leaks. Discharge and
Insufficient cooling the specified amount.
Discharge (High Gauge) Pressure Clogged or defective expansion Replace the expansion valve.
Abnormally Low. valve.
Low pressure gauge indicates
vacuum.
Discharge (High Gauge) Pressure Restriction caused by debris or Check system for restriction and
Abnormally Low. moisture in the receiver/drier. replace the receiver/drier.
Frost or dew on refrigerant line
before and after the receiver/drier or
expansion valve, and low pressure
gauge indicates vacuum.
Discharge (High Gauge) Pressure Compressor seal defective Repair or replace the compressor.
Abnormally Low.
High and low pressure gauge Poor compression due to a defective Repair or replace the compressor.
balanced quickly. (After turned off compressor gasket.
A/C)
Suction (Low Gauge) Pressure Excessive refrigerant in system. Discharge and recover refrigerant
Low pressure gauge (Low pressure
gauge is lowered after condenser is
cooled by water.)
Suction (Low Gauge) Pressure Unsatisfactory valve operation due Replace the expansion valve.
Abnormally High. to defective temperature sensor of
Low pressure hose temperature. expansion valve.
(Low pressure hose temperature
compressor
around the com ressor refrigerant
line connector is lower than around Expansion valve opens too long. Replace the expansion valve.
evaporator.)
Suction (Low Gauge) Pressure Compressor gasket is defective. Repair or replace the compressor.
Abnormally High.
High and low pressure gauge
balanced quickly. (After turned off
A/C)
Suction (Low Gauge) Pressure Insufficient refrigerant in system. Check for leaks. Discharge and
Insufficient cooling. specified amount.
Suction (Low Gauge) Pressure Expansion valve clogged. Replace the expansion valve.
Abnormally Low.
Frost on the expansion valve inlet
line

Suction (Low Gauge) Pressure Receiver/Drier clogged. Replace the receiver/drier.
Abnormally Low
Receiver/drier inlet and outlet
refrigerant line temperature. (A
distinct difference in temperature
develops.)
Suction (Low Gauge) Pressure Expansion valve temperature sensor Replace the expansion valve.
Abnormally Low. is defective.
Expansion valve outlet refrigerant
line. (Not cold and low pressure
gauge indicates vacuum.)
Suction (Low Gauge) Pressure Clogged or blocked refrigerant line. Replace refrigerant line.
Abnormally Low.
When the refrigerant line is clogged
or blocked, the low pressure gauge
reading will decrease, or a vacuum
reading may be shown.
Suction (Low Gauge) Pressure Thermo switch defective. Replace thermo switch.
Abnormally Low.
Evaporator core is frozen.
Suction (Low Gauge) and Discharge Excessive refrigerant in system. Discharge and recover the
(High Gauge) Pressure Abnormally refrigerant, the Recharge to the
High. specified amount.
Insufficient cooling. Condenser clogged or dirty. Clean the condenser fin.
Suction (Low Gauge) and Discharge Air in system. Evacuate and charge refrigerant.
(High Gauge) Pressure Abnormally
High.
Suction (Low) pressure hose (Not
cold).
Suction (Low Gauge) and Discharge Insufficient refrigerant in system. Check for leaks. Discharge and
(High Gauge) Pressure Abnormally recover refrigerant. Recharge to
Low. specified amount.
Insufficient cooling
A/C — Air Conditioning
Magnetic Clutch Diagnosis
D08RY00547
When the air conditioning switch and the fan control knob Powertrain Control Module (PCM;V6-3.2L)/ Engine
(fan switch) are turned on with the engine running, current Control Module (ECM;L4-2.2L) is used to stop the air
flows through the thermostat and the compressor relay to conditioning temporarily by turning off the magnetic clutch
activate the magnetic clutch. in the prearranged conditions to reduce the engine load
The air conditioning can be stopped by turning of the air which is being caused by the rise in the engine coolant
conditioning switch or the fan control knob (fan switch). temperature, and the acceleration of the vehicle, etc.
However, even when the air conditioning is in operation, For the inspection of the relays, switches and units in the
the electronic thermostat, the pressure switch or the table, refer to “Individual Inspection” in this section.
Magnetic Clutch Does Not Run

Step Action Yes No
1 Are No. EB-7 (10A) fuse and No. EB-5 (15A) / EB-6 (15A) fuse
OK? Go to Step 2 Replace
2 Are heater (X-1), thermostat (X-8), and compressor (X-2) relays
OK? Go to Step 3 Replace
3 Is pressure switch OK? Switch defective
or insufficient
4 Are air conditioning switch and fan control lever (Fan Switch) OK? Go to Step 5 Replace
5 1. Turn the ignition switch “ON” (Engine is running).
2. Air conditioning switch and fan control lever (Fan Switch)
“ON”.
connector terminal No. E3-1.
6 Check to see if continuity between compressor side connector
terminal No. E3-1 and the magnetic clutch side connector
terminal.
Magnetic clutch Compressor
Is there a continuity? defective. defective.
7 Check to see it battery voltage is present at chassis side Open circuit
connector terminal No.I24-2. between No.EB-7
(10A) fuse and
Go to Step 8 No. I24-2.
8 Check to see if battery voltage is present at chassis side
Open circuit
connector terminal No. C11-1
between No.I24-1
Is there a battery voltage? Go to Step 9 and No. C11-1.
9 1. Disconnect thermostat relay (X-8). Open circuit
2. Check to see if battery voltage is present at the chassis side between No.
relay terminal NO. X8-2 EB-7 and C11-2
(10A) fuse and
Go to Step 10 No.X8-2.
10 Check to see if voltage (approx. 10V) is present between chassis
side relay terminal No. X8-5 and No. X8-3.
11 1. Reconnect thermostat relay and disconnect compressor relay
(X-2).
Open circuit
between No.
relay terminal No. X2-5.
EB-7 (10A) fuse
Is there a battery voltage? Go to Step 12 and No. X2-5.
12 Check to see if continuity between chassis side relay terminal No.
X2-1 and the chassis side connector terminal No. E3-1.
Magnetic Clutch Does Not Run (Cont’d)

Step Action Yes No
13 Check to see if battery voltage is present between chassis side
relay terminal No. X2-2 and No. X2-4.
14 Check to see if battery voltage is present at chassis side relay Open circuit
terminal No. X2-2. between No.
EB-7 (10A) fuse
Go to Step 16 and No. X2-2.
15 Check to see if battery voltage is present at chassis side Power train
connector terminal No. E21-F4 / C1-B14. control module
(PCM) defective.
Refer to Open circuit
Driveability and between No.
Emissions in X2-4 and No.
Engine section. E21-F4 / C1-B14.
16 Check to see if continuity between chassis side relay terminal No. Power train
X8-1 and chassis side connector terminal No. E21-F45 / C3-E15. control module
(PCM) defective.
Refer to
Driveability and
Emissions in
Engine section. Open circuit
17 Check to see if battery voltage is present at chassis side relay
Open circuit
terminal No.X8-5.
between No.X8-5
Is there a battery voltage? Go to Step 18 and C11-2.
18 1. Reconnect thermostat relay.
Open circuit
connector terminal No.C40-3.
between No.I24-1
Is there a battery voltage? Go to Step 19 and No.C40-3.
19 Check to see if battery voltage (appox 10V) is present at chassis Open circuit
side connector terminal No. C40-1. between No.
X8-3 and No.
Go to Step 20 C40-1.
20 Check to see if continuity between chassis side connector Open circuit
terminal No. C40-2 and No.I23-6. between No.
C40-2 and
No.I23-6 or poor
Electronic ground (Fan
thermostat Switch Ground
defective. Circuit).
Condenser Fan Diagnosis
While the air conditioning is ON, the cycling switch in the exceeds a set pressure value. The condenser fan stops
triple pressure switch senses the refrigerant pressure, when the air conditioning is turned “OFF” or when the
and activates the condenser fan to improve the cooling pressure goes down below the set pressure value.
capacity of the condenser when the refrigerant pressure
D08RY00548

Condenser fan does not run. – Refer to “Chart A”.
– Refer to “Chart B”.
Chart “A” Condenser Fan Does Not Run

Step Action Yes No
1 Are 30A fuse OK? Go to Step 2 Replace
2 Is relay (X-11) OK? Go to Step 3 Replace
3 Is pressure switch OK? Switch defective
or insufficient
4 Is air conditioning switch OK? Go to Step 5 Replace
5 Is fan motor OK? Go to Step 6 Replace
6 1. Disconnect condenser fan relay (X-11). Open circuit
2. Check to see if battery voltage is present at the chassis side between
relay terminal NO. X11-2 Condenser Fan
fuse (30A) and
Go to Step 7 No.X11-2.
7 1. Reconnect condenser fan relay (X-11).
2. Air conditioning switch “ON”.
3. Check to see if battery voltage is present at chassis side Open circuit
connector terminal No.C9-3. between I-24-1
Is there a battery voltage? Go to Step 8 and C9-3.
8 1. Air conditioning switch “OFF”.
2. Check to see if continuity between chassis side relay terminal
No.X11-5 and the chassis side connector terminal No.C9-4.
9 Check to see if continuity between chassis side connector Poor ground or
terminal No. C24-1 and chassis side relay terminal No.X11-1. open circuit
between chassis
side connector
terminal
No.X11-3 (or
No.C24-2) and
body ground
(No.C16). Open circuit.
Chart “B” Condenser Fan Does Not Stop

Step Action Yes No
1 1. Air conditioning switch “OFF”. Condenser fan
Triple pressure relay (X11)
Does condenser fan stop?
switch defective. defective.
Air Source Select Lever Diagnosis
D08RY00549

FRESH mode inoperative — Refer to Chart A
RECIRC mode inoperative — Refer to Chart B
Chart “A”: FRESH Mode Inoperative

1 Is the fuse EB-7 normal? Replace the
2 Is C-16 grounded securely? Ground it
— Go to Step 3 securely
3 Remove the intake actuator relay.
Replace the
Is the relay normal? — Go to Step 4 relay
4 Is there continuity between the intake actuator relay
harness side connector C-42 terminal 4/5 and the Repair an
ground C-16? — Go to Step 5 open circuit
5 1. Set the HVAC control bezel to DEF/FOOT or DEF
position.
2. Turn the starter switch on and keep the engine
running.
Is the battery voltage applied between the intake
actuator harness side connector C-42 terminal 2 and
the ground? Approx. 12V Go to Step 10 Go to Step 6
6 Disconnect the HVAC control bezel.
Is the battery voltage applied between the bezel
harness side connector I-33 terminal 6 and the ground? Approx. 12V Go to Step 8 Go to Step 7
7 Repair an open circuit between the fuse EB-7 and the
connector I-33 terminal 6.
8 Is there continuity between the HVAC control bezel Repair or
side connector terminal 5 and 6? replace the
— Go to Step 9 bezel
9 Is there continuity between the harness side connector Repair an
I-33 terminal 5 and C-42 terminal 2? — Go to Step 10 open circuit
10 Disconnect the intake actuator connector C-39.
Is the battery voltage applied between the harness side Repair an
connector C-39 terminal 3 and the ground? Approx. 12V Go to Step 11 open circuit
C-39 terminal 2 and C-42 terminal 1 Approx. 12V Go to Step 12 open circuit
C–39 terminal 4 and 5? — Go to Step 13 open circuit
13 Replace the intake actuator.
Chart “B”: RECIRC Mode Inoperative

1 Is the fuse EB-7 normal? Replace the
2 Is C-16 grounded securely? Ground it
— Go to Step 3 securely
3 Is the Intake actuator relay normal? Replace the
4 1. Disconnect the Intake actuator connector C-39
2. Connect the battery positive terminal to the Intake
actuator side connector terminal No.3 and the
battery negative terminal to terminal No.6.
3. Connect the switch side connector terminal No.4
and No.5. Replace the
Does the actuator work normally? — Go to Step 5 actuator
5 Turn the Starter switch on.
Is the battery voltage applied to the harness side Repair an
connector C-39 terminal 3? Approx.12V Go to Step 6 open circuit
6 Is there continuity between harness side connector Repair an
C–42 terminal No.5 and the ground? — Go to Step 7 open circuit
7 1. Remove the HVAC control bezel.
2. Move the air source select lever to REC position. Repair or
Is there continuity between the control bezel side replace the
terminal No.3 and 8? — Go to Step 8 control bezel
8 Is there continuity between harness side connector Repair an
C-39 terminal 6 and connector I-33 terminal 3? — Go to Step 9 open circuit
9 Repair an open circuit between connector I-33 terminal
8 and connector C-42 terminal 3.
Individual Inspection Pressure Switch

Fan Control Knob (Fan Switch) And Air 1. Disconnect pressure switch connector and check for
continuity between pressure switch side connector
Conditioning (A/C) Switch terminals (1) and (2).
1. Check for continuity between the fan switch and the
A/C switch side connector terminals.
875RY00009
D08RW061
1. Disconnect the connector and check for continuity
Heater (X-1), Thermostat (X-8), Condenser between pressure switch side connector terminals (1)
Fan (X-11) And Compressor (X-2) Relay and (2).
1. Disconnect relays and check for continuity and 2. Reconnect the connector to activate the A/C switch,
resistance between relay terminals. and check to see if there is continuity between the
D For handling of these relays, refer to Heater Relay chassis side connector terminals (3) and (4) and the
in this section. fan operates.
875RY00010
825RS179
Condenser Fan D Keep moisture and contaminants out of the system.
When disconnecting or removing any lines or parts,
1. Disconnect the condenser fan connector. use plugs or caps to close the fittings immediately.
2. Connect the battery positive terminal to the Never remove the caps or plugs until the lines or parts
condenser fan side connector terminal No.C-24-1 are reconnected or installed.
and negative to the No.C-24-2.
D When disconnecting or reconnecting the lines, use
3. Check that condenser fan is rotating correctly. two wrenches to support the line fitting, to prevent
from twisting or other damage.
D Always install new O-rings whenever a connection is
disassembled.
D Before connecting any hoses or lines, apply new
specified compressor oil to the O-rings.
D When removing and replacing any parts which
require discharging the refrigerant circuit, the
operations described in this section must be
performed in the following sequence:
1. Use the J-39500 (ACR4: HFC-134a Refrigerant
Recovery / Recycling / Recharging / System) or
equivalent to thoroughly discharge and recover the
refrigerant.
2. Remove and replace the defective part.
3. After evacuation, charge the air conditioning
system and check for leaks.
Repair Of Refrigerant Leaks

875RW010
Refrigerant Line Connections
Install new O-rings, if required. When disconnecting or
General Repair Procedure connecting lines, use two wrenches to prevent the
Precautions For Replacement or Repair of connecting portion from twisting or becoming damaged.
There are certain procedures, practices and precautions
that should be followed when servicing air conditioning
systems:
D Keep your work area clean.
D Always wear safety goggle and protective gloves
when working on refrigerant systems.
D Beware of the danger of carbon monoxide fumes
caused by running the engine.
D Beware of discharged refrigerant in enclosed or
improperly ventilated garages.
D Always disconnect the negative battery cable and
discharge and recover the refrigerant whenever
repairing the air conditioning system.
D When discharging and recovering the refrigerant, do
not allow refrigerant to discharge too fast; it will draw
compressor oil out of the system.
852RS003
When connecting the refrigerant line at a block joint, Insert the nut into the union.
securely insert the projecting portion of the joint portion First, tighten the nut by hand as much as possible, then
into the connecting hole on the unit side and secure with a tighten the nut to the specified torque.
bolt. Apply the specified compressor oil to the O-rings
prior to connecting.
CAUTION: Compressor (PAG) oil to be used varies
according to the compressor model. Be sure to apply
oil specified for the model of compressor.
850RW004
850RW002
O-rings (2) must be fitted in the groove (1) of refrigerant

line.
850RW003
Leak Check
Inspection of refrigerant leak
Refrigerant leak may cause an adverse effect not only on
the performance and durability of each component of the
air–conditioner, but also on the global atmosphere.
Therefore, it is most important to repair refrigerant leak
when there is any leak found.
Inspection flow of refrigerant leak

Step Action Yes No
1 1. Evacuate the refrigerant system.
2. Charge the refrigerant.
Repair refrigerant
Is there any refrigerant leak? system. Go to Step 2.
2 1. Operate the compressor for more than 5 minutes to raise the
Compressor
pressure on the high pressure side.
Repair refrigerant operation to be
Is there any refrigerant leak at high pressure components? system. confirmed.
Inspection Steps D Welds of condenser body

Check the components of air–conditioner to see if there Receiver driver
occurs any refrigerant leak along the flow of refrigerant. D Pipe connection
NOTE: D Attaching section of pressure switch
D To avoid an error in the detection of refrigerant leak, D Section around the sight glass
make sure of there being no refrigerant vapor or Evaporator unit (cooling unit)
cigarette smoke around the vehicle before
conducting the inspection. Also, select a location D Pipe connections
where the refrigerant vapor will not get blown off with D Connections of expansion valve
wind. D Brazed sections of evaporator
D Inspection should be conducted chiefly on the pipe
NOTE:
connections and sections where a marked oil
contamination is found. When refrigerant is leaking, D The evaporator and expansion valve are contained in
oil inside is also leaking at the same time. the case. Remove the drain hose or the resistor of the
D It is possible to visually check the leak from inside the cooling unit and insert a leak detector when checking
cooling unit. Follow the method below when for any leak.
checking. Remove the drain hose or resistor of the Flexible hose
cooling unit, and insert a leak detector to see if there D Pipe connection
occurs any leak.
D Caulking section of the hose
High Pressure Side
D Hose (cracks, pinholes, flaws)
1. Discharger section of compressor. Pipe
2. Inlet/outlet section of condenser.
D Pipe connection
3. Inlet/outlet section of receiver driver.
D Pipe (cracks, flaws)
4. Inlet section of cooling unit.
Charge valve
Low Pressure Side
NOTE:
1. Outlet section of cooling unit.
2. Intake section of compressor. D The charge valve, which is used to connect the gauge
manifold, is normally provided with a resin cap. When
the valve inside gets deteriorated, refrigerant will leak
Major Checking Points of Refrigerant Leak out.
Compressor
D Pipe connection Leak at Refrigerant Line Connections
D Sealing section of shaft 1. Check the torque on the refrigerant line fitting and, if
D Mating section or cylinder too loose, tighten to the specified torque.
Condenser
to the line.
D Pipe connection
D Do not over tighten.
2. Perform a leak test on the refrigerant line fitting. WARNING:
3. If the leak is still present, discharge and recover the D SHOULD HFC-134A CONTACT YOUR EYE(S),
refrigerant from the system. CONSULT A DOCTOR IMMEDIATELY.
4. Replace the O-rings. D DO NOT RUB THE AFFECTED EYE(S). INSTEAD,
D O-rings cannot be reused. Always replace with new SPLASH QUANTITIES OF FRESH COLD WATER
ones. OVER THE AFFECTED AREA TO GRADUALLY
D Be sure to apply the specified compressor oil to the RAISE THE TEMPERATURE OF THE
new O-rings. REFRIGERANT ABOVE THE FREEZING POINT.
D OBTAIN PROPER MEDICAL TREATMENT AS
5. Retighten the refrigerant line fitting to the specified
SOON AS POSSIBLE. SHOULD THE HFC-134A
torque.
TOUCH THE SKIN, THE INJURY MUST BE
D Use two wrenches to prevent twisting and damage TREATED THE SAME AS SKIN WHICH HAS BEEN
to the line. FROSTBITTEN OR FROZEN.
6. Evacuate, charge and retest the system.
Refrigerant Recovery
Leaks In The Hose The refrigerant must be discharged and recovered by
If the compressor inlet or outlet hose is leaking, the entire using the J-39500 (ACR4:HFC-134a Refrigerant
hose must be replaced. The refrigerant hose must not be Recovery/Recycling/Recharging/System) or equivalent
cut or spliced for repair. before removing or mounting air conditioning parts.
1. Locate the leak. 1. Connect the high and low charging hoses of the
2. Discharge and recover the refrigerant. ACR4(or equivalent) as shown below.
3. Remove the hose assembly.
D Cap the open connections at once.
4. Connect the new hose assembly.
D Use two wrenches to prevent twisting or damage to
the hose fitting.
D Tighten the hose fitting to the specified torque.
5. Evacuate, charge and test the system.
Compressor Leaks
If leaks are located around the compressor shaft seal or
shell, replace or repair the compressor.
Recovery, Recycling, Evacuation and

Charging of HFC-134a
Air conditioning systems contain HFC-134a. This is a
chemical mixture which requires special handling
procedures to avoid personal injury.
D Always wear safety goggles and protective gloves.
D Always work in a well-ventilated area. Do not weld or
steam clean on or near any vehicle-installed air
conditioning lines or components.
D If HFC-134a should come in contact with any part of
the body, flush the exposed area with cold water and
immediately seek medical help.
D If it is necessary to transport or carry any container of
HFC-134a in a vehicle, do not carry it in the
passenger compartment.
D If it is necessary to fill a small HFC-134a container 901RS181
from a large one, never fill the container completely. Legend

Space should always be allowed above the liquid for (1) Low Side
expansion.
(2) High Side
D HFC-134a and R-12 should never be mixed as their
compositions are not the same. 2. Recover the refrigerant by following the
D HFC-134a PAG oil tends to absorb moisture more Manufacturer’s Instructions.
quickly than R-12 mineral oil and, therefore, should 3. When a part is removed, put a cap or a plug on the
be handled more carefully. connecting portion so that dust, dirt or moisture
D Keep HFC-134a containers stored below 40°C cannot get into it.
(104°F).
Refrigerant Recycling 8. If no leaks are found, again operate the vacuum pump
Recycle the refrigerant recovered by J-39500 for 20 minutes or more. After confirming that the
gauge manifold pressure is at 750 mmHg (30 inHg),
(ACR4:HFC-134a Refrigerant Recovery / Recycling /
close both hand valves.
Recharging / System) or equivalent.
For the details of the actual operation, follow the steps in 9. Close positive shutoff valve. Stop the vacuum pump
the ACR4(or equivalent) Manufacturer’s Instructions. and disconnect the center hose from the vacuum
pump.
Evacuation of The Refrigerant System
Charging The Refrigerant System
There are various methods of charging refrigerant into the
air conditioning system.
These include using J-39500 (ACR4:HFC-134a
Refrigerant Recovery/Recycling/Recharging/System) or
equivalent and direct charging with a weight scale
charging station.
Charging Procedure
D ACR4(or equivalent) Method
For the charging of refrigerant recovered by ACR4(or
equivalent), follow the manufacturer’s instruction.
901RS182
Legend
(1) Low Side
(2) High Side
NOTE: Explained below is a method using a vacuum

pump. Refer to the ACR4(or equivalent) manufacturer’s
instructions when evacuating the system with a ACR4(or
equivalent).
Air and moisture in the refrigerant will cause problems in
the air conditioning system. Therefore, before charging
the refrigerant, be sure to evacuate air and moisture thor-
oughly from the system.
1. Connect the gauge manifold.
D High-pressure valve (HI) — Discharge-side.
D Low-pressure valve (LOW) — Suction-side.
2. Discharge and recover the refrigerant.
3. Connect the center hose of the gauge manifold set to
the vacuum pump inlet.
4. Operate the vacuum pump, open shutoff valve and
901RS183
then open both hand valves.
5. When the low-pressure gauge indicates Legend
approximately 750 mmHg (30 inHg), continue the (1) Low Side
evacuation for 5 minutes or more. (2) High Side
6. Close both hand valves and stop the vacuum pump.
D Direct charging with a weight scale charging
7. Check to ensure that the pressure does not change
station method
after 10 minutes or more.
D If the pressure changes, check the system for 1. Make sure the evacuation process is correctly
leaks. completed.
2. Connect the center hose of the manifold gauge to the
D If leaks occur, retighten the refrigerant line
weight scale.
connections and repeat the evacuation steps.
3. Connect the low pressure charging hose of the
manifold gauge to the low pressure side service valve
of the vehicle.
4. Connect the high pressure charging hose of the
manifold gauge to the high pressure side service
valve of the vehicle.
901RS144
6. Perform a system leak test:

D Charge the system with approximately 200 g
(0.44 lbs) of HFC-134a.
D Make sure the high pressure valve of the manifold
gauge is closed.
D Check to ensure that the degree of pressure does
not change.
D Check for refrigerant leaks by using a HFC-134a
leak detector.
D If a leak occurs, recover the refrigerant. Repair the
leak and start all over again from the first step of
evacuation.
7. If no leaks are found, continue charging refrigerant to
the air conditioning system.
901RS184 D Charge the refrigerant until the scale reading
Legend decreases by the amount of the charge specified.
(1) Low Side Specified amount: 650 g (1.43 lbs)
(2) High Side D If charging the system becomes difficult:
(3) Refrigerant Container
1. Run the engine at idle and close all the vehicle
(4) Weight Scale
doors.
5. Place the refrigerant container(3) up right on a weight 2. Turn A/C switch “ON”.
scale(4). 3. Set the fan switch to its highest position.
Note the total weight before charging the refrigerant. 4. Set the air source selector lever to “CIRC”.
a. Open the refrigerant container valve. 5. Slowly open the low side valve on the manifold
b. Open the low side vale on the manifold gauge set. gauge set.
Refer to the manufacturer’s instructions for a WARNING: BE ABSOLUTELY SURE NOT TO OPEN
weight scale charging station. THE HIGH PRESSURE VALVE OF THE MANIFOLD
GAUGE. SHOULD THE HIGH PRESSURE VALVE BE
OPENED, THE HIGH PRESSURE REFRIGERANT
WOULD FLOW BACKWARD, AND THIS MAY CAUSE
THE REFRIGERANT CONTAINER TO BURST.
8. When finished with the refrigerant charging, close the
low pressure valve of the manifold gauge and
container valve.
9. Check for refrigerant leaks.
Checking The A/C System

1. Run the engine and close all the vehicle doors.
2. Turn A/C switch “ON”, set the fan switch to its highest
position.
3. Set the air source lever to “CIRC”, set the
temperature lever to the full cool position.
4. Check the high and low pressure of the manifold
gauge.
D Immediately after charging refrigerant, both high
and low pressures might be slightly high, but they
settle down to the pressure guidelines shown
below:
D The ambient temperature should be between
25–30°C (77–86°F).
D The pressure guideline for the high-pressure side is
approximately 1372.9–1863.3 kPa (199.1–270.2
psi).
D The pressure guideline for the low-pressure side is
approximately 147.1–294.2 kPa (21.3–42.7 psi).
D If an abnormal pressure is found, refer to Checking
The Refrigerant System With Manifold Gauge in
this section.
5. Put your hand in front of the air outlet and move the
temperature control lever of the control panel to
different positions. Check if the outlet temperature
changes as selected by the control knob.
Compressor Assembly
Compressor Assembly and Associated Parts
852RY00018
Legend (5) To Evaporator

(1) Compressor Bracket (6) Suction Line (Low-Pressure Hose)
(2) Magnetic Clutch Harness Connector (7) Discharge Line (High-Pressure Hose)
(3) Compressor (8) To Condenser
(4) O-ring (9) Serpentine Belt
Removal
2. Discharge and recover refrigerant
3. Disconnect magnetic clutch harness connector.
4. Remove serpentine belt. 4. Connect magnetic clutch harness connector.
wrench then remove serpentine belt. New Compressor Installation
The new compressor is filled with 150cc (5.0fl.oz.)of
compressor oil and nitrogen gas. When mounting the
compressor on the vehicle, perform the following steps;
1. Gently release nitrogen gas from the new
compressor.
D Take care not to let the compressor oil flow out.
D Inspect O-rings and replace if necessary.
850RY00005
Legend
(1) Auto Tensioner
(2) Idle Pulley
(4) Serpentine Belt
871RX033
2. Turn the compressor several times by hand and
(8) Generator release the compressor oil in the rotor.
3. When installing on a new system, the compressor
5. Disconnect refrigerant line connector.
should installed as it is. When installing on a used
D When removing the line connector, the connecting system, the compressor should be installed after
part should immediately be plugged or capped to adjusting the amount of compressor oil. (Refer to
prevent foreign matter from being mixed into the Compressor in this section)
line.
6. Remove compressor.
Installation
1. Install compressor.
D Tighten the compressor fixing bolts to the specified
torque.
2. Connect refrigerant line connector.
D Tighten the refrigerant line connector fixing bolts to
D O-rings cannot be reused. Always replace with new
ones.
D Be sure to apply new compressor oil to the O-rings
when connecting refrigerant lines.
871RX035
3. Install serpentine belt.
position.
Condenser Assembly
Condenser Assembly and Associated Parts
875RY00008

(1) Engine Hood Lock (5) Engine Hood Front End Stay
(2) Pressure Switch Connector (6) Condenser Assembly
(3) Refrigerant Line
1. Disconnect the battery ground cable. 1. Install condenser assembly.
2. Discharge and recover refrigerant. D If installing a new condenser, be sure to add 30cc
D Refer to Refrigerant Recovery in this section. (1.0 fl. oz.) of new compressor oil to a new one.
3. Remove radiator grille. D Tighten the condenser fixing bolts to the specified
4. Remove engine hood front end stay. torque.
5. Remove engine hood lock. Torque: 6 N•m (52 lb in)
D Apply setting mark to the engine hood lock fixing 2. Connect refrigerant line.
position before removing it. D Tighten the inlet line connector fixing bolt to the
6. Disconnect pressure switch connector. specified torque.
7. Disconnect refrigerant line. Torque: 15 N•m (11 lb ft)
D When removing the line connector, the connecting D Tighten the outlet line connector fixing bolt to the
part should immediately be plugged or capped to specified torque.
prevent foreign matter from being mixed into the
line. Torque: 6 N•m (52 lb in)
8. Remove condenser assembly. D O-rings cannot be reused. Always replace with new
D Handle with care to prevent damaging the ones.
condenser or radiator fin.
D Be sure to apply new compressor oil to the O-rings 4. Install engine hood lock.
when connecting the refrigerant line. 5. Install engine hood front end stay.
3. Connect pressure switch connector. 6. Install radiator grille.
Condenser Fan Motor

Condenser Fan Motor and Associated Parts
875RY00007

(1) Condenser Fan Assembly (4) Shroud
(2) Condenser Fan Motor (5) Fan
Removal 6. Remove fan.

D Remove the fan fixing C-ring and plate.
7. Remove condenser fan motor.
3. Remove radiator grille. Installation
4. Remove condenser fan assembly. To install, follow the removal steps in the reverse order,
D Disconnect the fan motor connector and remove
the 4 fixing bolts. 1. Route the fan motor harness in its previous position,
and fix it securely with clip and bracket.
5. Remove shroud.
D Remove the 3 fixing nuts.
D Loosen the condenser fixing nut and disconnect the
fan motor connector from bracket.
Receiver / Drier
Receiver / Drier and Associated Parts Installation
1. If installing a new receiver/drier, be sure to add 30cc
(1.0 fl. oz.) of new compressor oil to a new one.
2. Put the receiver/drier in the bracket and connect with
the refrigerant line. Check that no excessive force is
imposed on the line. Fasten the bracket bolt to the
receiver/drier.
3. Tighten the refrigerant line to the specified torque.
ones.
when connecting the refrigerant line.
875RY00012
Legend
(1) Pressure Switch Connector
(2) Refrigerant Line
(3) Radiator Grille
(4) Receiver / Drier
(5) Bracket Bolt
Removal
4. Disconnect pressure switch connector.
5. Disconnect refrigerant line.
D When removing the line connected part, the
into the line.
6. Remove bracket bolt.
7. Remove receiver/drier.
D Loosen the bolt, then, using care not to touch or
bend the refrigerant line, carefully pull out the
receiver/drier.
Pressure Switch
Pressure Switch and Associated Parts Installation
1. O-ring cannot be reused. Always replace with a new
one.
2. Be sure to apply new compressor oil to the O-ring
when connecting pressure switch.
3. Tighten the pressure switch to the specified torque.
875RY00013
Legend
(1) Pressure Switch Connector
(2) Pressure Switch
(3) Radiator Grille
Removal
D Refer to “Refrigerant Recovery in this section.
4. Disconnect pressure switch connector.
5. Disconnect pressure switch.
D When removing the switch connected part, the
into the line.
Evaporator Assembly
Evaporator Assembly and Associated Parts
874RY00017
Legend (3) Refrigerant Line

(1) Resistor and Electronic Thermostat Connector (4) Glove Box
(2) Drain Hose (5) Evaporator Assembly
Removal
4. Disconnect resistor (2) and electronic thermostat
connector (1).
874RY00021
5. Disconnect drain hose. 1. To install a new evaporator assembly, add 50cc
6. Disconnect refrigerant line. (1.7 fl. oz.) of new compressor oil to the new core.
D Use a back-up wrench when disconnecting and 2. Tighten the refrigerant outlet line to the specified
reconnecting the refrigerant lines. torque.
D When removing the refrigerant line connected part, Torque: 25 N•m (18 lb ft)
the connecting part should immediately be plugged 3. Tighten the refrigerant inlet line to the specified
or capped to prevent foreign matter from being torque.
ones.
Installation 5. Be sure to apply new compressor oil to the O-rings
To install, follow the removal steps in the reverse order, when connecting lines.
Electronic Thermostat, Evaporator Core and/or Expansion Valve

Disassembled View
874RX001
Legend (6) Clip

(1) Lining (7) Attaching Screw
(2) Expansion Valve (8) Evaporator Core
(3) O-ring (9) Electronic Thermostat
(4) Evaporator Assembly (10) Upper Case
(5) Lower Case
Removal 9. Remove evaporator core.

4. Remove the electronic thermostat sensor fixing clip.
Pull the sensor from the evaporator assembly.
5. Remove clip.
7. Remove upper case.
D Slit the case parting face with a knife since the lining
is separated when removing the evaporator.
874RY00006
10. Remove expansion valve.

D Tear off the insulator carefully.
D Remove the sensor fixing clip.
D Use a back-up wrench when disconnecting all
refrigerant pipes.
Installation
1. The sensor is installed on the core with the clip.
2. The sensor must not interfere with the evaporator
core.
3. When installing the new evaporator core, install the
874RS006
duct sensor (2) to the evaporator core (1) specified
D Lift to remove the upper case. position with the clip in the illustration.
874RY00005 874RY00016
4. O-rings cannot be reused. Always replace with new 7. To install a new evaporator core, add 50cc (1.7 fl. oz.)
ones. of new compressor oil to the new core.
5. Be sure to apply new compressor oil to the O-rings 8. Tighten the refrigerant lines to the specified torque.
when connecting lines. Refer to Main Data and Specifications for Torque
6. Be sure to install the sensor and the insulator on the Specifications in this section.
place where they were before. 9. Apply an adhesive to the parting face of the lining
when assembling the evaporator assembly.
Refrigerant Line
852RY00020
Legend (3) Discharge Line (High-Pressure Hose)

(1) Clip and Clamp (4) Radiator Grille
(2) Liquid Line (High-Pressure Pipe) (5) Suction Line (Low-Pressure Pipe)
Removal D When removing the refrigerant line connecting part,

the connecting part should immediately be plugged
1. Disconnect the battery ground cable. or capped to prevent foreign matter from being
2. Discharge and recover refrigerant. mixed into the line.
3. Remove radiator grille. Installation
4. Remove clip and clamp. To install, follow the removal steps in the reverse order,
5. Disconnect liquid line (High-pressure pipe). noting the following point:
6. Disconnect suction line (Low-pressure pipe) using a 1. O-rings cannot be reused. Always replace with new
back-up wrench. ones.
7. Disconnect suction line (Low-pressure hose) using a 2. Be sure to apply new compressor oil to the O-rings
back-up wrench. when connecting lines.
8. Disconnect discharge line (High-pressure hose) 3. Tighten the refrigerant line to the specified torque.
using a back-up wrench. Refer to Main Data and Specifications for Torque
D Use a backup wrench when disconnecting and Specifications in this section.
reconnecting the refrigerant lines.
Main Data And Specifications

Heater Unit
Temperature control Reheat air mix system
Capacity 4.3 kw (3700 Kcal./hr.)
Air flow 280 m#/h
HEATER CORE
Type Fin and tube type
Radiating area Approx. 2.4 m@
EVAPORATOR ASSEMBLY
Capacity 4.8 kw (4100 Kcal./hr.)
Air flow 430 m#/hr
EVAPORATOR CORE
Type Al-laminate louver fin type
EXPANSION VALVE
Type External pressure equalizer type
THERMOSTAT SWITCH
Type Electronic thermostat
OFF: Below 1.0 ± 0.5 °C (33.8 ± 0.9 °F)
ON: Above 3.5 ± 0.3 °C (38.3 ± 0.9 °F)
CONDENSER
Type Parallel flow type
Radiation performance 12.9 kw (11,100 Kcal./hr.)
RECEIVER/DRIER
Type Assembly includes sight glass with dual (triple) pres-
sure switch (V6) or pressure sensor (L4)
Internal volume 300 cc (10 fl.oz.)
PRESSURE SWITCH
Type Dual pressure switch
ON: 205.9±29.4 kPa (29.9±4.3 psi)
OFF: 176.5±24.5 kPa (25.6±3.6 psi)
ON: 2353.6±196.1 kPa (341.3±28.4 psi)
OFF: 2942.0±196.1 kPa (426.6±28.4 psi)
Triple pressure switch (V6, A/T)
ON: 196.3±29.4 kPa (27.0±4.3 psi)
OFF: 176.5±19.6 kPa (25.6±2.8 psi)
Medium pressure control
ON: 1471.0±98.1 kPa (213.3±14.2 psi)
OFF: 1078.7±117.7 kPa (156.4±17.7 psi)
ON: 2353.6±196.1 kPa (341.3±28.4 psi)
OFF: 2942.0±196.1 kPa (426.6±28.4 psi)
REFRIGERANT
Type HFC-134a
Specified amount 650 g (1.43 lbs.)
852RY00019
874RX006
Compressor
Service Precaution see if the drive plate can be rotated. If rotation is
impossible, the compressor is seized. Low discharge
WARNING: THIS VEHICLE HAS A SUPPLEMENTAL pressure may be due to a faulty internal seal of the
RESTRAINT SYSTEM (SRS). REFER TO THE SRS compressor, or a restriction in the compressor. Low
COMPONENT LOCATION VIEW IN ORDER TO discharge pressure may also be due to an insufficient
DETERMINE WHETHER YOU ARE PERFORMING refrigerant charge or a restriction elsewhere in the
SERVICE ON OR NEAR THE SRS COMPONENTS OR system. These possibilities should be checked prior to
THE SRS WIRING. WHEN YOU ARE PERFORMING servicing the compressor. If the compressor is
SERVICE ON OR NEAR THE SRS COMPONENTS OR inoperative, but is not seized, check to see if current is
THE SRS WIRING, REFER TO THE SRS ON-VEHICLE being supplied to the magnetic clutch coil terminals.
SERVICE INFORMATION. FAILURE TO FOLLOW The compressor oil used in the HFC–134a system
CAUTIONS COULD RESULT IN POSSIBLE AIR BAG compressor differs from that used in R–12 systems.
DEPLOYMENT, PERSONAL INJURY, OR Also, compressor oil to be used varies according to the
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. compressor model. Be sure to avoid mixing two or more
different types of oil.
CAUTION: Always use the correct fastener in the If the wrong oil is used, lubrication will be poor and the
proper location. When you replace a fastener, use compressor will seize or malfunction.
ISUZU will call out those fasteners that require a DKV-14G Type Compressor
replacement after removal. ISUZU will also call out DKV–14G is equipped with five–vane rotary compressor.
the fasteners that require thread lockers or thread These vanes are built into a rotor which is mounted on a
sealant. UNLESS OTHERWISE SPECIFIED, do not shaft.
use supplemental coatings (paints, greases, or other When the shaft rotates, the vanes built into the cylinder
corrosion inhibitors) on threaded fasteners or block assembly are operated by centrifugal force.
fastener joint interfaces. Generally, such coatings This changes the volume of the spare formed by the rotor
adversely affect the fastener torque and the joint and cylinder, resulting in the intake and compression of
clamping force, and may damage the fastener. When the refrigerant gas. The discharge valve and the valve
you install fasteners, use the correct tightening stopper, which protects the discharge valve, are built into
sequence and specifications. Following these the cylinder block assembly. There is no suction valve but
instructions can help you avoid damage to parts and a shaft seal is installed between the shaft and head; a
systems. trigger valve, which applies back pressure to the vanes, is
General Description installed in the cylinder block and a refrigerant gas
temperature sensor is installed in the front head.
When servicing the compressor, keep dirt or foreign
The specified quantity of compressor oil is contained in
material from getting on or into the compressor parts and
system. Clean tools and a clean work area are important the compressor to lubricate the various parts using the
for proper service. The compressor connections and the refrigerant gas discharge pressure.
outside of the compressor should be cleaned before any
”On–Vehicle” repair, or before removal of the
compressor. The parts must be kept clean at all times and
any parts to be reassembled should be cleaned with
Trichloroethane, naphtha, kerosene, or equivalent
solvent, and dried with dry air. Use only lint free cloths to
wipe parts.
The operations described below are based on bench
overhaul with compressor removed from the vehicle,
except as noted. They have been prepared in order of
accessibility of the components. When the compressor is
removed from the vehicle for servicing, the oil remaining
in the compressor should be discarded and new
compressor oil added to the compressor.
Compressor malfunction will appear in one of four ways:
noise, seizure, leakage or low discharge pressure.
Resonant compressor noises are not cause for alarm;
however, irregular noise or rattles may indicate broken
parts or excessive clearances due to wear. To check
seizure, de–energize the magnetic clutch and check to
871RX002
Diagnosis
Noise from compression Defective rotor/piston Replace compressor/cylinder and
shaft assembly
Defective shaft Replace compressor/cylinder and
shaft assembly
Noise from magnetic clutch Defective bearing Replace magnetic clutch
Defective clutch Replace magnetic clutch
Clearance between drive plate and Adjust the clearance or replace
pulley not standard magnetic clutch
Insufficient cooling Defective gasket Replace compressor/gasket
Defective rotor/reed valve Replace compressor/valve plate
Defective trigger valve/suction valve Replace compressor/suction valve
Not rotating Defective rotor/piston Replace compressor/cylinder and
shaft assembly
Defective shaft Replace compressor/cylinder and
shaft assembly
Rotating parts seized due to Replace compressor
insufficient oil
Oil and/or gas leakage Defective seal Replace compressor/shaft seal
Defective O-ring Replace
Magnetic Clutch Assembly (DKV-14G Type)

Parts Location View
871RX025
Legend (4) Pulley Assembly

(1) Drive Plate bolt (5) Field Coil
(2) Drive Plate (6) Shim (s)
(3) Snap Ring (7) Lead Wire
Removal 2. Remove drive plate by using drive plate puller

J-33944-A (2) and forcing screw J-33944-4 (1).
1. Using drive plate holder J-33939 (1) to prevent the
drive plate from rotating, then remove the drive plate
bolt.
871RX023
871RX029
3. Remove shim (s). 6. Loosen screw and disconnect the field coil wire
4. Remove snap ring (1) by using snap ring pliers. connector.
871RY00030
871RY00029
5. Remove pulley assembly by using pulley puller pilot 7. Loosen three screws and remove the field coil.
J-38424 (2), pulley puller J-8433 (1) and pulley puller
leg J-24092-2 (3).
871RY00034
871RY00033
Inspection and Repair 3. Install pulley assembly by using pulley installer

J-33940-A (2) and drive handle J-8092 (1).
Drive Plate
If the frictional surface shows signs of damage due to
excessive heat, the drive plate and pulley should be
replaced.
Pulley Assembly
Check the appearance of the pulley assembly. If the
frictional surface of the pulley shows signs of excessive
grooving due to slippage, both the pulley and drive plate
should be replaced. The frictional surfaces of the pulley
assembly should be cleaned with a suitable solvent
before reinstallation.
Coil
Check coil for loose connector or cracked insulation.
Installation
1. Install field coil.
871RY00032
D Align the located portion (1) of the field coil and 4. Install snap ring.
compressor.
5. Install shim (s).
6. Install the drive plate to the compressor drive shaft
together with the original shim(s)(1). Press the drive
plate by hand.
871RY00035
D Tighten the mounting screw to the specified torque.

Torque: 5N·m (44 lb in)
2. Connect the lead wire connector with the rubber hold 871RY00031
and tighten the screw.

7. Install drive plate bolt by using drive plate holder D Check to be sure that the clutch clearance is
J-33939 (1) to prevent the drive plate from rotating. between 0.3-0.6 mm (0.01-0.02 in.)
871RX029 871RY00028
D Tighten the drive plate bolt to the specified torque.

Legend
Torque: 13 N·m (113 lb in) (1) Dial Gauge
D After tightening the drive plate bolt, check to be sure (2) Pulley Assembly
the pulley rotates smoothly. (3) Field Coil Wire Connector
D If necessary, install adjusting shim(s).

D Adjusting shims are available in the following
thickness.
Thickness
D 0.1 mm (0.0039 in.)
D 0.3 mm (0.0118 in.)
D 0.5 mm (0.0197 in.)
Compressor Oil
Oil Specification 6. Adjust the oil level following the next procedure
below.
D The HFC-134a system requires a synthetic (PAG)
compressor oil whereas the R-12 system requires a (Charging Amount) (Collected Amount)
mineral compressor oil. The two oils must never be
more than 90cc (3.0 same as collected
mixed.
fl.oz) amount
D Compressor (PAG) oil varies according to
compressor model. Be sure to use oil specified for the less than 90 cc (3.0 fl.oz) 90cc (3.0 fl.oz)
model of compressor.
D Always use HFC-134a Vane Rotary Type 7. Install the compressor, then evacuate, charge and
Compressor Oil (AIPDN Part No.2-90188-301-0) perform the oil return operation.
8. Check system operation.
Handling of Oil
D The oil should be free from moisture, dust, metal When it is impossible to preform oil return operation,
powder, etc. the compressor oil should be checked in the
D Do not mix with other oil. following order:
D The water content in the oil increases when exposed 1. Discharge and recover refrigerant and remove the
to the air. After use, seal oil from air immediately. compressor.
(HFC-134a Vane Rotary Compressor Oil absorbs 2. Drain the compressor oil and measure the extracted
moisture very easily.) oil with a measuring cylinder.
D The compressor oil must be stored in steel 3. Check the oil for contamination.
containers, not in plastic containers. 4. If more than 90 cc (3.0 fl. oz.) of oil is extracted from
the compressor, supply the same amount of oil to the
compressor to be installed.
Compressor Oil Check
5. If the amount of oil extracted is less than 90 cc (3.0 fl.
The oil used to lubricate the compressor is circulating with oz.), recheck the compressor oil in the following
the refrigerant. order.
Whenever replacing any component of the system or a
large amount of gas leakage occurs, add oil to maintain 6. Supply 90 cc (3.0 fl. oz.) of oil to the compressor and
the original amount of oil. install it onto the vehicle.
Oil Capacity 7. Evacuate and recharge with the proper amount of
refrigerant.
Capacity total in system: 150cc (5.0 fl.oz)
8. Perform the oil return operation.
Compressor (Service parts) charging amount:
150 cc (5.0 fl.oz) 9. Remove the compressor and recheck the amount of
oil.
10. Adjust the compressor oil, if necessary.
Checking and Adjusting Oil Quantity
for Used Compressor (Collected Amount) (Charging Amount)
more than 90 cc (3.0 same as collected
1. Perform oil return operation. Refer to Oil Return
fl.oz) amount
Operation in this section.
2. Discharge and recover refrigerant and remove the less than 90 cc (3.0 fl.oz) 90 cc (3.0 fl.oz)
compressor.
4. If the amount of oil drained is much less than 90 cc
(3.0 fl. oz.), some refrigerant may have leaked out.
Conduct a leak tests on the connections of each
system, and if necessary, repair or replace faulty
parts.
5. Check the compressor oil contamination. (Refer to
Contamination of Compressor Oil in this section.)
Checking and Adjusting for Replacement of Component Parts

Compressor Replacement When replacing the system component parts, supply the
150 cc (5.0 fl.oz.) of oil is charged in compressor (service following amount of oil to the component parts to be
parts). So it is necessary to drain the proper amount of oil installed.
from the new compressor. (Component parts to be (Amount of Oil)
1. Perform oil return operation. installed)
2. Discharge and recover the refrigerant and remove the Evaporator 50 cc (1.7 fl. oz.)
compressor.
Condenser 30 cc (1.0 fl. oz.)
oil. Receiver/dryer 30 cc (1.0 fl. oz.)
4. Check the compressor oil for contamination. Refrigerant line (one 10 cc (0.3 fl. oz.)
5. Adjust the oil level as required. piece)
(Amount of oil drained (Draining amount of oil

from used compressor) from new compressor)
less than 90 cc (3.0 fl.oz) Same as drained
amount
more than 90 cc (3.0 90 cc (3.0 fl.oz)
fl.oz)
6. Evacuate, charge and perform the oil return

operation.
7. Check the system operation.
Contamination of Compressor Oil

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

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

COMPRESSOR
Model DKV-14G
Type Vane rotary type
Number of vanes 5
Rotor diameter 64 mm (2.52 in.)
Stroke 8.75 mm (0.34 in.)
Displacement 140 cc (47.3 fl.oz.)
Maximum speed 7,000 rpm (up to 8,400 rpm)
Direction of rotation Clockwise (Front-side view)
Lubrication system Pressure differential type
Lubricant R-134a Vane Rotary Type Compressor Oil
(AIPDN Part No.2-90188-301-0)
150 cc (5.0 fl.oz.)
Refrigerant Refrigerant-134a (R-134a), 650 g (1.43 lbs.)
Shaft seal Lip type
Weight 3.5 kg
MAGNETIC CLUTCH
Type Electromagnetic single-plate dry clutch
Rated voltage 12 Volts D.C.
Current consumption 3.7 A
Starting torque 49 N·m (36 lb·ft)
Direction of rotation Clockwise (Front-side view)
Weight 3.0 kg (6.6 lbs.)
871RX028
Special Tools
TOOL NO. TOOL NO.
TOOL NAME TOOL NAME
J-33939 J-33940-A
Drive plate holder Pulley installer
J-33944-A J-8092
Drive plate puller Drive handle
J-33944-4
Forcing screw
J-38424
Pulley puller pilot
J-8433
Pulley puller
J-24092-2
Pulley puller leg
POWER–ASSISTED STEERING SYSTEM 2A–1
RODEO
STEERING
POWER-ASSISTED STEERING SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 2A–2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–27
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–2 Inspection and Repair . . . . . . . . . . . . . . . . . . 2A–27
General Description . . . . . . . . . . . . . . . . . . . . . 2A–8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–27
Power Steering System Test . . . . . . . . . . . . . . 2A–10 Supplemental Restraint System Steering
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–11 Wheel & Column . . . . . . . . . . . . . . . . . . . . . . . 2A–28
Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–11 Service Precaution . . . . . . . . . . . . . . . . . . . . 2A–28
Bleeding The Power Steering System . . . . . . 2A–11 SRS Connectors . . . . . . . . . . . . . . . . . . . . . . 2A–28
Bleeding Procedure . . . . . . . . . . . . . . . . . . . . . 2A–11 Inflator Module . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–30
Flushing The Power Steering System . . . . . . 2A–11 Inflator Module and Associated Parts . . . . . 2A–30
Steering Wheel Free Play Inspection . . . . . . 2A–12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–30
Front End Alignment Inspection and Inspection and Repair . . . . . . . . . . . . . . . . . . 2A–31
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–31
Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . 2A–32
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–17
Steering Wheel and Associated Parts . . . . 2A–32
Power Steering Unit . . . . . . . . . . . . . . . . . . . . . 2A–18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–32
Power Steering Unit and Associated Parts 2A–18 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–18
Combination Switch . . . . . . . . . . . . . . . . . . . . . 2A–35
Installation (4×2 Model) . . . . . . . . . . . . . . . . 2A–19
Combination Switch and Associated Parts 2A–35
Installation (4×4 Model) . . . . . . . . . . . . . . . . 2A–19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–35
Power Steering Unit Disassembled View . . 2A–20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–37
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–20
Lock Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–39
Lock Cylinder and Associated Parts . . . . . . 2A–39
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–39
Main Data and Specifications . . . . . . . . . . . 2A–21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–41
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–21
System Inspection . . . . . . . . . . . . . . . . . . . . . 2A–42
Power Steering Pump . . . . . . . . . . . . . . . . . . . . 2A–22
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . 2A–43
Power Steering Pump and Associated Parts 2A–22
Steering Column and Associated Parts . . . 2A–43
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–43
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–22
Insepction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–45
Power Steering Pump Disassembled View 2A–23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–47
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–23
System Inspection . . . . . . . . . . . . . . . . . . . . . 2A–48
Supplemental Restraint System Steering
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–24
Wheel & Column and Associated Parts . . . . 2A–49
Transfer Gear Assembly . . . . . . . . . . . . . . . . . 2A–27
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–49
Transfer Gear Assembly and Associated
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A–27
2A–2 POWER–ASSISTED STEERING SYSTEM
Service Precaution Diagnosis

WARNING: THIS VEHICLE HAS A SUPPLEMENTAL Since the problems in steering, suspension, wheels and
RESTRAINT SYSTEM (SRS). REFER TO THE SRS tires involve several systems, they must all be considered
COMPONENT AND WIRING LOCATION VIEW IN when diagnosing a complaint. To identify the symptom,
ORDER TO DETERMINE WHETHER YOU ARE always road test the vehicle first. Proceed with the
PERFORMING SERVICE ON OR NEAR THE SRS following preliminary inspections and correct any defects
COMPONENTS OR THE SRS WIRING. WHEN YOU which are found.
ARE PERFORMING SERVICE ON OR NEAR THE SRS 1. Inspect tires for proper pressure and uneven wear.
COMPONENTS OR THE SRS WIRING, REFER TO 2. Raise vehicle on a hoist, then inspect front and rear
THE SRS SERVICE INFORMATION. FAILURE TO suspension and steering linkage for loose or
FOLLOW WARNINGS COULD RESULT IN POSSIBLE damaged parts.
AIR BAG DEPLOYMENT, PERSONAL INJURY, OR 3. Spin the front wheels. Inspect for out-of-round tires,
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. out-of-balance tires, loose and/or rough wheel
CAUTION: Always use the correct fastener in the bearings.
systems.
General Diagnosis
Parts in power steering valve Replace power steering unit.
defective.

wheel.
Worn upper or lower end ball joints. Replace ball joints.
Excessive wheel run–out. Repair or replace wheel and/or tire.
Excessive loaded radial run–out of Replace tire or wheel.
Loose steering unit. Tighten steering unit.
defective.
upper or lower end ball joint.
Improper power steering system Repair or replace.
operation.
Refer to “Power steering system
diagnosis”
Loose steering unit or linkage. Retighten or repair.
universal joint.
Bind in upper or lower end ball joints. Replace ball joints.

bushing.
wheel nut holes.
Replace wheel if required.
bearings.
Loose steering unit. Retighten mounting bolt.
Faulty steering unit. Replace steering unit.
pressure.
bushings.
Power Steering System

There is some noise in all power steering systems. One between this noise and steering performance. Do not
of the most common is a hissing sound when the steering replace the valve unless the “hissing” noise is extremely
wheel is fully turned and the car is not moving. This noise objectionable. A replacement valve will also have a slight
will be most evident when the steering wheel is operated noise, and is not always a cure for the condition.
while the brakes are applied. There is no relationship
Rattle or Chucking Noise Pressure hose touching other parts Adjust hose position. Do not bend
of vehicle. tubing by hand.
Tie rod ends loose. Tighten or replace tie rod end.
Loose steering unit mounting. Tighten steering unit mounting.
Poor Return of Steering Wheel to Improper front wheel alignment. Adjust front wheel alignment.
Center
Wheel bearing worn. Replace front wheel bearing.
Tie rod end binding. Replace tie rod end.
Ball joint binding. Replace ball joint.
Tight or frozen steering shaft Replace steering assembly.
bearing.
Sticky or plugged steering unit valve. Flush or replace steering unit.
Entry of air in the power steering Bleed the system.
system.
Momentary Increase In Effort When High internal leakage. Repair steering gear.
Turning Wheel Fast To Right or Left
Steering Wheel Surges or Jerks Insufficient pump pressure. Repair pump assembly.
When Turning Especially During
Sticky steering unit valve. Flush or replace steering unit.
Parking
Excessive Wheel Kick Back or Loose Air in system. Bleed hydraulic system.
Steering
Tie rod end loose. Tighten tie rod end.
Wheel bearing worn. Replace wheel bearing.
Hard Steering or Lack or Power Sticky steering unit valve. Flush or replace steering unit.
Assist
Insufficient pump pressure. Repair pump assembly.
Excessive internal pump leakage. Repair pump assembly.
Excessive internal steering gear Repair steering gear.
leakage.
Unstable Engine Idling or Stalling Pressure switch of the power Repair or replace.
When Turning steering pump or its harness is faulty.
Power Steering Pump
Foaming milky power steering fluid, low fluid level, and fluid level is low. If the fluid level is correct and the pump
possible low pressure can be caused by air in the fluid, or still foams, remove the pump from the vehicle and check
loss of fluid due to internal pump leakage. Check for leak housing for cracks. If the housing is cracked, replace the
and correct. Bleed the system. Extremely cold pump housing.
temperatures will cause air bubbles in the system if the
Low Pressure Due to Steering Pump Relief valve sticking or inoperative. Replace relief valve.
Side plate not flat against cam ring. Replace side plate.
Extreme wear of cam ring. Replace cam ring.
Vanes sticking in rotor slots. Repair or replace vanes and rotor.
Cracked or broken side plate. Replace side plate.
High internal leakage. Repair internal leakage.
Low Pressure Due to Steering Gear Scored housing bore. Replace housing.
Growling Noise In Steering Pump Excessive back pressure in hoses or Repair steering unit or pump.
steering unit caused by restriction.
Worn cam ring. Replace cam ring.
Groaning Noise In Steering Pump Air in the fluid. Bleed hydraulic system.
Low fluid level. Replenish fluid.
Pump mounting loose. Tighten mounting bolt.
Rattling Noise In Steering Pump Vanes sticking in rotor slots. Repair or replace vanes and rotor.
Vane improperly installed. Repair rotor and vane.
Swishing Noise In Steering Pump Damaged relief valve. Replace relief valve.
Whining Noise In Steering Pump Scored side plate and vanes. Replace side plate and vanes.
Steering Column Lock System

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

This diagnosis covers mechanical problems only. Refer
to Turn Signal Switch in Electrical section for electrical
diagnosis.
Turn Signal Will Not Stay In Turn Foreign material or loose parts Repair or replace signal switch.
Position preventing movement of yoke.
Broken or missing detent or Replace signal switch.
canceling spring.
Turn Signal Will Not Cancel Loose switch mounting screws. Tighten mounting screws.
Switch or anchor bosses broken. Replace turn signal switch.
Broken, missing or out of position Replace turn signal switch.
detent, return or canceling spring.
Worn canceling cam. Replace turn signal switch.
Turn Signal Difficult To Operate Turn signal switch arm loose. Tighten arm screw.
Broken or distorted yoke. Replace turn signal switch.
Loose or misplaced springs. Replace turn signal switch.
Foreign parts and/or material. Repair turn signal switch.
Loose turn signal switch mounting Tighten mounting screws.
screws.
Turn Signal Will Not Indicate Lane Broken lane change pressure pad or Replace turn signal switch.
Change spring hanger.
Broken, missing or misplaced lane Replace turn signal switch.
change spring.
Base of wire damaged. Replace turn signal switch.
Hazard Switch Cannot Be Turned Off Foreign material between hazard Repair or replace hazard switch.
switch to turn signal switch body.
No Turn Signal Lights Electrical failure in chassis harness. Refer to Electrical section.
Inoperative turn signal flasher unit. Replace flasher unit.
Front or Rear Turn Signal Lights Not Burned-out or damaged turn signal Replace bulb.
Flashing bulb.
High resistance connection to Repair bulb socket.
ground at bulb socket.
General Description
The hydraulic power steering system consists of a pump,
an oil reservoir, a steering unit, a pressure hose and a
return hose.
Power Steering Unit
A02RW001
The power steering unit is rack and pinion type.

The toe–in angle can be adjusted by turning the rod on
each side.
The steering housing cannot be disassembled.
Hydraulic Pump
A02RX002
The hydraulic pump is vane-type design. The submerged Pressure Switch
pump has housing and internal parts that are inside the When hydraulic pressure reaches 3430 kPa (500 psi), the
reservoir and operate submerged in oil. There are two pressure switch of the power steering pump closes
bore openings at the rear of the pump housing. The larger causing the Engine Control Module (ECM) to actuate the
opening contains the cam ring, pressure plate, thrust idle air control valve, which increases the engine rpm to
plate, rotor and vane assembly, and end plate. The prevent the overload-induced engine speed slow down.
smaller opening contains the pressure line union, flow The switch opens when hydraulic pressure drops to 2940
control valve and spring. kPa (430 psi).
The flow control orifice is part of the pressure line union.
The pressure relief valve inside the flow control valve
limits the pump pressure.
Steering Column
431RY00004
WARNING: TO AVOID DEPLOYMENT WHEN INSTRUCTION IN THIS MANUAL MUST BE

TROUBLE-SHOOTING THE SRS SYSTEM, DO NOT FOLLOWED CAREFULLY, OTHERWISE PERSONAL
USE ELECTRICAL TEST EQUIPMENT, SUCH AS INJURY MAY RESULT.
BATTERY-POWERED OR A/C-POWERED When servicing a vehicle equipped with Supplemental
VOLT-METER, OHMMETER, ETC., OR ANY TYPE OF Restraint System, pay close attention to all WARNINGS
ELECTRICAL EQUIPMENT OTHER THAN and CAUTIONS.
For detailed explanation about SRS, refer to Restraints
NON-POWERED PROBE-TYPE TESTER.
section.
The steering column has three important features in The column can be disassembled and reassembled.
addition to the steering function: However, to insure the energy absorbing action, use only
1. The column is energy absorbing, designed to the specified screws, bolts and nuts as designated, and
compress in a front-end collision to minimize the tighten them to the specified torque.
possibility of injury to the driver of the vehicle. Handle the column with care when it is removed from the
2. The ignition switch and lock are mounted vehicle. A sharp blow on the end of steering shaft or shift
conveniently on the column. lever, or dropping the assembly could shear or loosen the
fasteners that maintain column rigidity.
3. With the column mounted lock, the ignition and
steering operation can be locked to prevent theft of
the vehicle.
Power Steering System Test

Test Procedure
C02RW001
Legend (2) Power Steering Unit

(1) Fluid Reservoir (3) Power Steering Pump
Test of fluid pressure in the power steering system is 1. Place a container under the pump to catch the fluid
performed to determine whether or not the oil pump and when disconnecting or connecting the hoses.
power steering unit are functioning normally. 2. With the engine NOT running, disconnect the
The power steering system test is used to identify and pressure hose at the power steering pump and install
isolate hydraulic circuit difficulties. Prior to performing power steering tester J-29877-A. The gage must be
this test, the following inspections and corrections, if between the shutoff valve and pump. Open the
necessary, must be made. shutoff valve.
D Inspect pump reservoir for proper fluid level. 3. Check the fluid level. Fill the reservoir with power
D Inspect pump belt for proper tension. steering fluid, to the “Full” mark. Start the engine,
D Inspect pump driver pulley condition. then turn the steering wheel and momentarily hold it
against a stop (right or left). Turn the engine off and
check the connections at tester for leakage.
4. Bleed the system. Refer to Bleeding the Power Fluid Level
Steering System in this section.
5. Start the engine and check the fluid level. Add power 1. Run the engine until the power steering fluid reaches
steering fluid if required. When the engine is at normal operating temperature, about 55°C (130°F),
normal operating temperature, increase engine then shut the engine off.
speed to 1500 rpm. 2. Check the level of fluid in the reservoir.
CAUTION: Do not leave shutoff valve fully closed 3. If the fluid level is low, add power steering fluid as
for more than 5 seconds, as the pump could become specified in General Information to the proper level
damaged internally. and install the receiver cap.
6. Fully close the shutoff valve. Record the highest 4. When checking the fluid level after the steering
pressures. system has been serviced, air must be bled from the
system. Refer to Bleeding the Power Steering
D If the pressure recorded is within 9300–9800 kPa System in this section.
(1350–1420 psi), the pump is functioning within its
specifications.
D If the pressure recorded is higher than 9800 kPa Bleeding The Power Steering System
(1420 psi), the valve in the pump is defective. When a power steering pump or unit has been installed,
or an oil line has been disconnected, the air that has
D If the pressure recorded is lower than 9300 kPa
entered the system must be bled out before the vehicle is
(1350 psi), the valve or the rotating group in the
operated. If air is allowed to remain in the power steering
pump is defective.
fluid system, noisy and unsatisfactory operation of the
7. If the pump pressures are within specifications, leave system may result.
the valve open and turn (or have someone else turn)
the steering wheel fully in both directions. Record the
highest pressures and compare with the maximum Bleeding Procedure
pump pressure recorded in step 6. If this pressure When bleeding the system, and any time fluid is added to
cannot be built in either side of the power steering the power steering system, be sure to use only power
unit, the power steering unit is leaking internally and steering fluid as specified in General Information.
must be replaced. 1. Fill the pump fluid reservoir to the proper level and let
8. Shut the engine off, remove the testing gauge. the fluid settle for at least two minutes.
9. Reconnect the pressure hose, check the fluid level 2. Start the engine and let it run for a few seconds. Do
and make the needed repairs. not turn the steering wheel. Then turn the engine off.
10. If the problem still exists, the steering and front 3. Add fluid if necessary.
suspension must be thoroughly examined. 4. Repeat the above procedure until the fluid level
remains constant after running the engine.
Maintenance 5. Raise and support the front end of the vehicle so that
the wheels are off the ground.
The hydraulic system should be kept clean and fluid level
in the reservoir should be checked at regular intervals and 6. Start the engine. Slowly turn the steering wheel right
fluid added when required. Refer to Recommended and left, lightly contacting the wheel stops.
Fluids and Lubricants in General Information section for 7. Add power steering fluid if necessary.
the type of fluid to be used and the intervals for filling. 8. Lower the vehicle, set the steering wheel at the
If the system contains some dirt, flush it as described in straight forward position after turning it to its full steer
this section. If it is exceptionally dirty, the pump must be positions 2 or 3 times, and stop the engine.
completely disassembled before further usage. (The
9. Check the fluid level and refill as required.
steering unit cannot be disassembled.)
All tubes, hoses, and fittings should be inspected for 10. If the fluid is extremely foamy, allow the vehicle to set
leakage at regular intervals. Fittings must be tight. Make a few minutes, then repeat the above procedure.
sure the clips, clamps and supporting tubes and hoses
are in place and properly secured.
Power steering hoses and lines must not be twisted,
Flushing The Power Steering System
kinked or tightly bent. Air in the system will cause spongy 1. Raise and support the front end of the vehicle off the
action and noisy operation. When a hose is disconnected ground until the wheels are free to turn.
or when fluid is lost, for any reason, the system must be 2. Remove the fluid return line at the pump inlet
bled after refilling. Refer to Bleeding the Power Steering connector and plug the connector port on the pump.
Position the line toward a large container to catch the
D Inspect belt for tightness. draining fluid.
D Inspect pulley for looseness or damage. The pulley
3. While running the engine at idle, fill the reservoir with
should not wobble with the engine running.
new power steering fluid. Turn the steering wheel in
D Inspect hoses so they are not touching any other both directions. Do not contact or hold the steering
parts of the vehicle. wheel to the wheel stops. This will cause the pump to
D Inspect fluid level and fill to the proper level. go to pressure relief mode, which may cause a
sudden fluid overflow at the reservoir.
4. Install all the lines and hoses. Fill the system with new Camber:
power steering fluid and bleed the system as This illustration shows view from the front of the vehicle.
described in Bleeding The Power Steering System.
Operate the engine for about 15 minutes.
Remove the pump return line at the pump inlet and
plug the connection on the pump. While refilling the
reservoir, check the draining fluid for contamination.
If foreign material is still evident, replace all lines,
disassemble and clean or replace the power steering
system components. Do not re-use any drained
power steering fluid.
Steering Wheel Free Play Inspection
480RS004
Camber is the vertical tilting inward or outward of the front

wheels. When the wheels tilt outward at the top, the
camber is positive (+). When the wheels tilt inward at the
top, the camber is negative (-). The amount of tilt
measured in degrees from the vertical is called the
camber angle (1). If camber is extreme or unequal
between the wheels, improper steering and excessive tire
wear will result. Negative camber causes wear on the
inside of the tire, while positive camber causes wear to the
outside.
430RX003
Caster:
1. With the tires in the straight-ahead position, check the This illustration shows view from the side of the vehicle.
amount of steering wheel play by turning the wheel in
both directions until the tires begin to move.
NOTE: The wheel free play should be checked with the
engine running.
Free play: 0 – 30 mm (0 – 1.18 in)
2. Also check the steering wheel for play and looseness
in the mount by moving it back and forth and
sideways. When test driving, check for hard steering,
steering shimmy and tendency to pull to one side.
Front End Alignment Inspection and

Adjustment
General Description
“Front End Alignment” refers to the angular relationship
between the front wheels, the front suspension attaching
parts and the ground.
Proper front end alignment must be maintained in order to 480RS005
insure efficient steering, good directional stability and to

prevent abnormal tire wear.
The most important factors of front end alignment are
wheel toe-in, wheel camber and axle caster.
Caster (1) is the vertical tilting of the wheel axis either 6. Inspect the wheel and tires for run-out. Refer to
forward or backward (when viewed from the side of the Wheel Replacement in Wheel and Tire System
vehicle). A backward tilt is positive (+) and a forward tilt is section.
negative (-). On the short and long arm type suspension 7. Inspect the trim height. If not within specifications,
you cannot see a caster angle without a special the correction must be made before adjusting caster.
instrument, but if you look straight down from the top of 8. Inspect the steering unit for looseness at the frame.
the upper control arm to the ground, the ball joints do not
9. Inspect shock absorbers for leaks or any noticeable
line up (fore and aft) when a caster angle other than 0
noise. Refer to Shock Absorber in Suspension
degree is present. With a positive angle, the lower ball section.
joint would be slightly ahead (toward the front of the
vehicle) of the upper ball joint center line. 10. Inspect the control arms or stabilizer bar attachment
for looseness. Refer to Suspension section .
Toe-in:
11. Inspect the front end alignment using alignment
This illustration shows view from the top of the vehicle. equipment. Follow the manufacturer’s instructions.
12. Park the vehicle must be on a level surface.
Trim Height Adjustment

Adjust the trim height (1) by means of the adjusting bolt on
the height control arms.
CAUTION: When adjusting front end alignment, be
sure to begin with trim height first, as it may change
other adjusted alignments.
480RS003
Toe-in is the measured amount the front wheels are turn

in. The actual amount of toe-in is normally a fraction of a
degree. Toe-in is measured from the center of the tire
treads or from the inside of the tires. The purpose of
toe-in is to insure parallel rolling of the front wheels and to
offset any small deflections of the wheel support system
which occurs when the vehicle is rolling forward.
Incorrect toe-in results in excessive toe-in and unstable
steering. Toe-in is the last alignment to be set in the front 450RS003
end alignment procedure.
Inspection
Before making any adjustments affecting caster, camber
or toe-in, the following front end inspection should be
made.
1. Inspect the tires for proper inflation pressure. Refer to
Main Data and Specifications in Wheel and Tire
System section.
2. Make sure that the vehicle is unladen condition (With
no passenger or loading).
3. Make sure that the spare tire is installed at the normal
position.
4. Inspect the front wheel bearings for proper
adjustment. Refer to Front Hub and Disc Overhaul in
Suspension section.
5. Inspect the ball joints and tie rod ends. If excessive
looseness is noted, correct before adjusting. Refer to
Steering Linkage in this section. 410RS001
1. Check and adjust the tire inflation pressures. NOTE: Difference of the caster shim front/rear thickness
2. Park the vehicle on a level ground and move the front should be 3.6 mm (0.142 in) or less. Overall thickness of
of the vehicle up and down several times to settle the caster shim and camber shim should be 10.8 mm
suspension. (0.425 in) or less.
3. Make necessary adjustment with the adjusting bolt on Tighten the fulcrum pin bolt to the specified torque.
the height control arms. Torque: 152 N·m 112 ( lb ft)
Trim height: 119 ± 5 mm (4.69 ± 0.2 in)
Camber Adjustment
Caster Adjustment The camber angle can be adjusted by means of the
The caster angle can be adjusted by means of the caster camber shims (2) installed in position between the
shims (1) installed between the chassis frame (2) and chassis frame (1) and fulcrum pins
fulcrum pins. Camber angle: 0° ± 30’
Caster angle: 2°30’ ± 1° King pin inclination: 12°30’ ± 30’
CAUTION: Left and right side must be equal within CAUTION: Left and right side must be equal within
30’. 30’.
450RW007
450RW006
450RS005
450RS002
NOTE: Overall thickness of caster shim and camber
shim should be 10.8 mm (0.425 in) or less.
Position of shims
Camber angle Caster angle
Front side Rear side
When added When removed Decreases Decreases
When removed When added Increases Increases
Caster shim
— When removed Unchanged Decreases
— When added Unchanged Increases
When added Decreases Unchanged
Camber shim
When removed Increases Unchanged
Toe-in Adjustment
1. To adjust the toe-in angle, loosen the lock nuts (2) on
the tie rod (1) and turn the tie rod. Turn both rods the
same amount, to keep the steering wheel centered .
Toe-in: 0 ± 2 mm (0 ± 0.08 in)
433RW003
2. Tighten the lock nut to the specified torque.


Caster 2°30’ ± 1°
Camber 0° ± 30’
King pin inclination 12°30’ ± 30’
Toe-in 0 ± 2 mm (0 ± 0.08 in)
Max. steering angle inside 32.6° (+0°30’ to –2°30’ )
outside 31.8°
E02RX001
Special Tools
TOOL NO.
ILLUSTRATION
TOOL NAME
J–29877–A
Tester;
Power steering
J–39213
Adapter;
Power steering tester
Power Steering Unit

Power Steering Unit and Associated Parts
431RW013
Legend (3) Power Steering Unit Assembly

(1) Bracket (4) Crossmember
(2) Transfer Gear Assembly
Removal
2. Remove the transfer gear assembly.
Make a setting mark across the coupling flange and
steering unit to ensure reassembly of the parts in the
original position.
3. Drain power steering fluid.
4. Remove the tie rod end assembly from knuckle.
Use tie rod end remover J–29107.
433RW002
5. Disconnect the feed line and return line from steering 5. Remove the power steering unit with the
unit. crossmember.
Remove the clips on the crossmember and frame. 6. Remove the power steering unit.
Wire the power steering line to frame. 4×2 model:
NOTE: Take care to prevent foreign matter from entry 1. Remove the power steering unit from the
when disconnect the power steering line. crossmember.
Installation (4×2 Model)

1. Install power steering unit to crossmember.
Tighten fixing bolt to specified torque.
2. Connect the feed line and return line.
3. Install tie–rod end assembly to knuckle.
4. Install transfer gear assembly.
Align the setting marks made at removal.
5. Install the stone guard.
6. Bleed the system.
Refer to Bleeding the Power Steering System in this
435RW001
section.
4×4 model:
1. Remove the torsion bar. Refer to Front Suspension in
Suspension section.
Installation (4×4 Model)
2. Remove the lower control arm bolt (Frame side). 1. Install power steering unit to crossmember.
Refer to Front Suspension in Suspension section. Tighten fixing bolt to specified torque.
3. Apply a setting mark across the crossmember and Torque: 116 N·m (85 lb ft)
frame so parts can be reassembled in their original 2. Install power steering unit with crossmember to frame
position. by aligning the setting marks made when removing.
Tighten crossmember mounting bolt to specified
torque.
3. Install lower control arm bolt.
Refer to Front Suspension in Suspension section.
4. Install torsion bar.
Refer to Front Suspension in Suspension section.
5. Connect the feed line and return line.
6. Install tie–rod end assembly to knuckle.
7. Install transfer gear assembly.
Align the setting marks made at removal.
8. Install the stone guard.
431RX013
9. Bleed the system.
4. Remove the crossmember fixing bolt. Refer to Bleeding the Power Steering System in this
section.
Power Steering Unit Disassembled View
440RW003
Legend (6) Tie-rod Assembly

(1) Tie-rod End (7) Tab Washer
(2) Lock Nut (8) Oil Line
(3) Clip (9) Valve Housing Assembly
(4) Bellows (10) Mounting Rubber
(5) Band (11) Dust Cover
Disassembly Tie-rod Assembly

If the resistance is insufficient or play is felt when checked
NOTE: The valve housing is made of aluminum and care
by moving the ball on the tie-rod, replace the tie-rod
should be exercised when clamping in a vise, etc. to
assembly.
prevent distortion or damage.
1. Loosen lock nut and remove tie–rod end. Rubber Parts
2. Remove clip and band, then remove bellows. If wear or damage is found through inspection, replace
3. Remove tie-rod assembly. with new ones.
To remove, move the boot toward the tie-rod end,
then remove tab washer. Reassembly
4. Remove oil line, mounting rubber and dust cover.
1. Install mounting rubber and dust cover (If removed).
2. Install oil line.
Inspection and Repair Torque: 13 N· m (113 lb in)
Inspect the following parts for wear, damage or any
3. Install tie-rod assembly with tab washer.
Apply grease to ball joint, install tie-rod and tab
Tie-rod End washer, then tighten to specified torque.
If looseness or play is found when checked by moving the Torque: 83 N·m (61 lb ft)
end of ball joint at tie-rod end, replace tie-rod end.
After tightening, bend tab washer against width
across flat of inner ball joint.
4. Apply a thin coat of grease to the shaft for smooth
installation. Then install bellows.
5. Install band and clip.
6. Install tie-rod end and tighten lock nut.

Power Steering unit Type Rack and pinion
Rack stroke 152 mm (5.98 in)
Lock to lock 3.64
E02RX002
Special Tools
TOOL NO.
ILLUSTRATION
TOOL NAME
J–29107
Tie rod end remover
Power Steering Pump

Power Steering Pump and Associated Parts
436RX001
Legend (3) Hose, Flexible

(1) Pump Assembly (4) Bolt
(2) Hose, Suction
1. Remove the drive belt. 1. Install the pump assembly to the pump braket, tighten
2. Place a drain pan below the pump. the fixing bolt to the specified torque.
3. Disconnect the suction hose. Torque: 46 N·m (34 lb ft)
4. Disconnect the flexible hose. 2. Install the flexible hose.
5. Remove the power steering fixing bolt and remove Tighten the eye bolt to specified torque.
the pump assembly. Torque: 54 N·m (40 lb ft)
3. Install the drive belt.
4. Connect the suction hose, then fill and bleed system.
Refer to Bleeding the Power Steering System in this
section.
Power Steering Pump Disassembled View
442RX001
Legend (12) Cam

(1) Bolt (13) Pump Cartridge Assembly
(2) Suction Pipe (14) O-ring
(3) O-ring (15) Snap Ring
(4) Shaft Assembly (16) Rear Housing
(5) Oil Seal (17) Bolt
(6) Front Housing (18) Spring
(7) O-ring (19) Relief Valve
(8) O-ring (20) O-ring
(9) Side Plate (21) Connector
(10) Rotor and Vane (22) Pressure Switch Assembly
(11) Pin
Disassembly 5. Remove the bolt, rear housing and O-ring.

1. Clean the oil pump with solvent (plug the discharge
and suction ports to prevent the entry of solvent). 7. Remove the shaft assembly.
Be careful not to expose the oil seal of shaft assembly 8. Remove the oil seal.
to solvent. CAUTION: When removing the oil seal, be careful
2. Remove the bolt, suction pipe and O-ring. not to damage the housing.
3. Remove the connector, O-ring, relief valve and 9. Remove the pump cartridge assembly from the front
spring. housing.
4. Remove the pressure switch assembly. 10. Remove two O-rings.
Inspection and Repair Sliding faces of the vane should be free from wear.
(Particularly the curved face at the tip that contact with the
Make all necessary adjustments, repairs, and part
cam should be free from wear and distortion). When part
replacements if wear, damage, or other problems are
Rotor
Cam
The inner face of the arm should have a uniform contact
pattern without a sign of step wear. When part
Side Plate
The sliding faces of parts must be free from step wear
(more than 0.01 mm), which can be felt by the finger nail.
The parts with minor scores may be reused after lapping
the face.
Relief Valve
The sliding face of the valve must be free from burrs and
damage. The parts with minor scores may be reused after
smoothing with emery cloth (#800 or finer).
Shaft
Oil seal sliding faces must be free from a step wear which
442RS002
Check that the groove in the vane is free from excessive can be felt by the finger nail. Bushing fitting face must be
wear and that the vane slides smoothly. When part free from damage and wear.
O-ring, Oil Seal, Snap Ring
Be sure to discard used parts, and always use new parts
Vane for installation. Prior to installation, lubricate all seals and
rings with power steering fluid.
Pressure Switch
Check the switch operation as follows:
With engine idling and A/C on, turn the steering wheel
fully to the left; compressor should interrupt and engine
idle speed will increase. Shut off A/C and again turn
steering fully to the left; engine idle will increase. If system
fails to function properly, disconnect connector at the
pressure switch and repeat system check while testing
continuity across disconnected SW connector.
Reassembly
1. Install oil seal to front housing. Be sure to discard
used oil seal, and always use new parts for
installation.
CAUTION: When installing the oil seal, be careful
not to damage the oil seal contacting surface of the
442RS003 housing.
2. Install shaft assembly.
3. Install the vanes to roter with curved face in contact
with the inner wall of cam.
442RS005
4. Install roter and vanes to cam.

5. Install pin to front housing.
6. Install two new O-rings to front housing. Be sure to
discard used O-ring.
7. Install side plate.
CAUTION: When installing side plate, be careful not
to damage its inner surface. Damaged side plate may
cause poor pump performance, pump seizure or oil
leakage.
8. Install pump cartridge assembly to front housing.
9. Install snap ring to shaft end.
10. Install rear housing with a new O-ring. Be sure to
discard used O-ring. Then install bolt and tighten it to
specified torque.
11. Install suction pipe with a new O-ring. Be sure to
discard used O-ring. Then install bolt and tighten it to
specified torque.
12. Install relief valve and spring.
13. Install connector with a new O-ring. Be sure to
discard used O-ring. Tighten the connector to
specified torque.
14. Install pressure switch assembly and tighten it to
specified torque.

Oil pump Type Vane
Operating ATF DEXRON–III
fluid
E02RX004
Transfer Gear Assembly

Transfer Gear Assembly and Associated Parts
441RW001
Legend (3) Fixing Bolt Nut

(1) Transfer Gear Assembly (4) Shim
(2) Bolt, Universal Joint (Steering Shaft Side) (5) Bolt, Universal Joint (Steering Unit Side)
1. Remove universal joint bolt (steering shaft side). 1. Install transfer gear assembly with shim and tighten
2. Remove universal joint bolt (steering unit side). bolt and nut to the specified torque.
3. Loosen fixing bolt and nut and remove transfer gear Torque: 54 N·m (40 lb ft)
assembly with shim. 2. Connect universal joint (both side) and tighten the bolt
The transfer gear assembly cannot be disassembled. If
damage or abnormal condition are found, replace to new
ones.
Supplemental Restraint System Steering Wheel & Column

Service Precaution WHEN CARRYING A LIVE AIR BAG ASSEMBLY,
MAKE SURE THE BAG AND TRIM COVER ARE
This steering wheel and column repair section covers the
POINTED AWAY FROM YOU. NEVER CARRY AN AIR
Supplemental Restraint System (SRS) steering column.
The following repair procedures are specific to SRS BAG ASSEMBLY BY THE WIRES OR CONNECTOR
components. When servicing a vehicle equipped with ON THE UNDERSIDE OF MODULE. IN THE CASE OF
Supplemental Restraint System, pay close attention to all AN ACCIDENTAL DEPLOYMENT, THE BAG WILL
WARNINGS and CAUTIONS. THEN DEPLOY WITH MINIMAL CHANCE OF INJURY.
For detailed explanation about SRS, refer to Restraints WHEN PLACING A LIVE AIR BAG ASSEMBLY ON A
section. BENCH OR OTHER SURFACE, ALWAYS FACE THE
BAG AND TRIM COVER UP, AWAY FROM THE
RESTRAINT SYSTEM (SRS). REFER TO THE SRS SURFACE.
COMPONENT AND WIRING LOCATION VIEW IN NEVER REST A STEERING COLUMN ASSEMBLY ON
ORDER TO DETERMINE WHETHER YOU ARE THE STEERING WHEEL WITH THE AIR BAG
PERFORMING SERVICE ON OR NEAR THE SRS ASSEMBLY FACE DOWN AND COLUMN VERTICAL.
COMPONENTS OR THE SRS WIRING. WHEN YOU THIS IS NECESSARY SO THAT A FREE SPACE IS
ARE PERFORMING SERVICE ON OR NEAR THE SRS PROVIDED TO ALLOW THE AIR BAG ASSEMBLY TO
COMPONENTS OR THE SRS WIRING, REFER TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL
THE SRS SERVICE INFORMATION. FAILURE TO DEPLOYMENT. OTHERWISE, PERSONAL INJURY
FOLLOW WARNINGS COULD RESULT IN POSSIBLE COULD RESULT.
OTHERWISE UNNEEDED SRS SYSTEM REPAIRS. TO AVOID DEPLOYMENT WHEN
TROUBLESHOOTING THE SRS SYSTEM, DO NOT
SAFE HANDLING OF INFLATOR MODULES USE ELECTRICAL TEST EQUIPMENT, SUCH AS
REQUIRES FOLLOWING THE PROCEDURES BATTERY-POWERED OR A/C-POWERED
DESCRIBED BELOW FOR BOTH LIVE AND VOLT-METER, OHMMETER, ETC., OR ANY TYPE OF
DEPLOYED MODULES. ELECTRICAL EQUIPMENT OTHER THAN
SAFETY PRECAUTIONS MUST BE FOLLOWED SPECIFIED IN THIS MANUAL. DO NOT USE A
WHEN HANDLING A DEPLOYED AIR BAG NON-POWERED PROBE-TYPE TESTER.
ASSEMBLY (AIR BAG). AFTER DEPLOYMENT, THE INSTRUCTIONS IN THIS MANUAL MUST BE
AIR BAG ASSEMBLY (AIR BAG) SURFACE MAY FOLLOWED CAREFULLY, OTHERWISE PERSONAL
CONTAIN A SMALL AMOUNT OF SODIUM INJURY MAY RESULT.
HYDROXIDE, A BY-PRODUCT OF THE
DEPLOYMENT REACTION, THAT IS IRRITATING TO SRS Connectors
THE SKIN AND EYES. MOST OF THE POWDER ON
THE AIR BAG ASSEMBLY (AIR BAG) IS HARMLESS. CAUTION: The special yellow color connectors are
used for supplemental restraint system-air bag
AS A PRECAUTION, WEAR GLOVES AND SAFETY
circuit.
GLASSES WHEN HANDLING A DEPLOYED AIR BAG
ASSEMBLY, AND WASH YOUR HANDS WITH MILD When removing the cable harness, do not pull the
cables. Otherwise, cable disconnection may occur.
SOAP AND WATER AFTERWARDS.
When connect the SRS connector, insert the connec-
tor completely. Imperfect locking may cause mal-
function of SRS circuit.
To remove the connector, hold the cover insulator(1) and To install the connector, hold the soket insulator(1) and
pull it. The cover insulator slides and lock will be released. insert it. The cover insulator slides and connector will be
Do not hold the socket insulator(2). locked.
Do not hold the cover insulator(2).
827RW028
827RW027
Inflator Module
Inflator Module and Associated Parts
827RW071
Legend (3) Fixing Bolt

(1) Horn Lead (4) Inflator Module
(2) SRS Connector
Removal
least 5 minutes.
from steering assembly .
827RW070
6. Disconnect the yellow 2-way SRS connector and The inflator module consists of a cover, air bag, inflator,
horn lead located behind the inflator module. and retainer. Inspect the inflator module mainly for the
following:
D Check for holes, cracks, severe blemishes and
deformation on the cover.
D Check that the retainer is not deformed.
D Check for defects such as damage and breakage in
the lead wire for the igniter.
If an abnormality is found as the result of the inspection,
replace the inflator module with a new one.
Installation
1. Install inflator module.
connector and horn lead.
being pinched.
827RW073
Inspection and Repair 5. Connect the battery “–” terminal cable.
WARNING: THE INFLATOR MODULE SHOULD 6. Set ignition to “ON” while watching warning light.
ALWAYS BE CARRIED WITH THE TRIM COVER Light should flash 7 times and then go off. If lamp
AWAY FROM YOUR BODY AND SHOULD ALWAYS does not operate correctly, refer to Restraints section.
BE LAID ON A FLAT SURFACE WITH THE
OTHERWISE, PERSONAL INJURY MAY RESULT .
827RW072
Steering Wheel
Steering Wheel and Associated Parts
827RW069
Legend (3) Steering Wheel

(1) Horn Lead (4) Steering Wheel Fixing Nut
(2) SRS Connector (5) Inflator Module
CAUTION: Once the steering column is removed Removal

from the vehicle, the column is extremely
susceptible to damage. Dropping the column 1. Turn the steering wheel so that the vehicle’s wheels
assembly on its end could collapse the steering shaft are pointing straight ahead.
or loosen the slide block which maintains column 2. Turn the ignition switch to “LOCK”.
rigidity. Leaning on the column assembly could 3. Disconnect the battery “–” terminal cable, and wait at
cause the jacket to bend or deform. Any of the above least 5 minutes.
damage could impair the column’s collapsible
design. If it is necessary to remove the steering 4. Disconnect the yellow 2-way SRS connector located
wheel, use only the specified steering wheel puller. under the steering column.
Under no conditions should the end of the shaft be
hammered upon, as hammering could loosen slide
block which maintains column rigidity.
equivalent until the inflator module can be released position, then remove steering wheel.
430RW021
827RW070 10. Move the front wheels to the straight ahead position,
WARNING: THE INFLATOR MODULE SHOULD CAUTION: Never apply force to the steering wheel
ALWAYS BE CARRIED WITH THE TRIM COVER in direction of the shaft by using a hammer or other
AWAY FROM YOUR BODY AND SHOULD ALWAYS impact tools in an attempt to remove the steering
BE LAID ON A FLAT SURFACE WITH THE wheel. The steering shaft is designed as an energy
URETHANE SIDE UP. THIS IS NECESSARY absorbing unit.
430RX005
827RW073
7. Disconnect horn lead.

8. Remove steering wheel fixing nut.
Installation
1. Install steering wheel by aligning the setting marks
made when removing.
absorbing unit.
torque.
4. Support the module and carefully connect the SRS
connector.
being pinches.
warning light. Light should flash 7 times and then go
off. If lamp does not operate correctly, refer to
Restraints section.
Combination Switch
Combination Switch and Associated Parts
431RX006
Legend (4) Combination Switch and SRS Coil Assembly

(1) Steering Column Cover (5) Instrument Panel Lower Cover
(2) Steering Wheel (6) Driver Knee Bolster (reinforcement)
(3) Inflator Module

1. Turn the steering wheel so that the vehicle’s wheels “LOCK” position before disconnecting the steering
least 5 minutes. 5. Remove the engine hood opening lever, then remove
4. Disconnect the yellow 2-way SRS connector located instrument panel lower cover.
under the steering column. 6. Remove the driver knee bolster (reinforcement).
7. Loosen the inflator module fixing bolt from behind the WARNING: THE INFLATOR MODULE SHOULD
steering wheel assembly using a TORX driver or ALWAYS BE CARRIED WITH THE TRIM COVER
equivalent until the inflator module can be released AWAY FROM YOUR BODY AND SHOULD ALWAYS
from steering assembly. Disconnect the yellow 2-way BE LAID ON A FLAT SURFACE WITH THE
SRS connector and horn lead located behind the URETHANE SIDE UP. THIS IS NECESSARY
inflator module, then remove inflator module. BECAUSE A FREE SPACE IS PROVIDED TO ALLOW
827RW070
827RW072

position, then use steering wheel remover J–29752 to
remove the steering wheel.
827RW073
430RW021
CAUTION: Never apply force to the steering wheel Installation
impact tools in an attempt to remove the steering 1. Install combination switch and SRS coil assembly.
wheel. The steering shaft is designed as an energy After installation of combination switch assembly,
absorbing unit. connect the combination switch wiring harness
under the steering column. Then turn the SRS coil
counter clockwise to full, return about 3 turns and
align the neutral mark.
CAUTION: When turning the SRS coil counter
clockwise to full, stop turning if resistance is felt.
Forced further turning may damage to the cable in
the SRS coil.
430RX005

under the steering column then remove combination
switch and SRS coil assembly.
combination switch assembly. 825RW016
825RW288
route each wire harness as illustrated so that the
harnesses do not catch on any moving parts.
825RW017
Legend
(2) Starter Switch Harness
(4) Inflator Module Harness
3. Align the setting marks made when removing then

install steering wheel.
absorbing unit.
torque.
5. Support the inflator module and carefully connect the
SRS connector and horn lead.
being pinched.
8. Install instrument panel lower cover then Install the
engine hood opening lever.
9. Connect the SRS connector.
10. Connect the battery “-” terminal cable.
warning light and check the light should flash 7 times
and then go off. If lamp does not operate correctly,
refer to Restraints section.
Lock Cylinder
Lock Cylinder and Associated Parts
431RX005
Legend (6) Cushion Rubber

(1) Inflator Module (7) Lock Cylinder Assembly
(2) Steering Wheel (8) Instrument Panel Lower Cover
(3) Steering Column Cover (9) Driver Knee Bolster (reinforcement)
(4) Combination Switch and SRS Coil Assembly (10) Shift Lock Cable (for A/T)
(5) Snap Ring

1. Turn the steering wheel so that the vehicle’s wheels ”LOCK” position before disconnecting the steering
least 5 minutes. 5. Remove the engine hood opening lever and steering
4. Disconnect the yellow 2-way SRS connector located lower cover.
under the steering column. 6. Remove driver knee bolster (reinforcement).
equivalent until the inflator module can be released position.
430RW021
827RW070 10. Move the front wheels to the straight ahead position,
8. Disconnect the yellow 2-way SRS connector and then use steering wheel remover J–29752 to remove
horn lead located behind the inflator module. the steering wheel.
absorbing unit.
827RW073
430RX005
WARNING: THE INFLATOR MODULE SHOULD 14. Remove snap ring.
ALWAYS BE CARRIED WITH THE TRIM COVER 15. Remove cushion rubber.
AWAY FROM YOUR BODY AND SHOULD ALWAYS
16. Remove shift lock cable (for A/T).
URETHANE SIDE UP. THIS IS NECESSARY 17. Disconnect the starter switch harness connector
BECAUSE A FREE SPACE IS PROVIDED TO ALLOW located under the steering column then remove lock
THE AIR CUSHION TO EXPAND IN THE UNLIKELY cylinder assembly.
Installation
1. Install lock cylinder assembly.
2. Install shift lock cable (for A/T).
3. Install cushion rubber.
6. Turn the SRS coil counter clockwise to full, return
about 3 turns and align the neutral mark.
CAUTION: When turning the SRS coil counter
clockwise to full, stop turning if resistance is felt.
Forced further turning may damage the cable in the
SRS coil.
827RW072

coil.
825RW016
825RW288
7. When installing the steering column cover, be sure to System Inspection
wire (through each harness) as illustrated so that the
harnesses starter switch, combination switch and Turn the ignition switch to “ON” while watching warning
SRS coil may not catch wiring. light.
825RW017
Legend
(2) Starter Switch Harness
(4) Inflator Module Harness
8. Install steering wheel by aligning the setting marks

made during removal.
absorbing unit.
torque.
10. Support inflator module and carefully connect the
SRS connector and horn lead, then install inflator
module.
being pinched.
11. Tighten fixing bolts to specified torque.
13. Install instrument panel lower cover, then install the
engine hood opening lever.
Steering Column
Steering Column and Associated Parts
431RX004
Legend (7) Lock Cylinder Assembly

(1) Inflator Module (8) Shift Lock Cable (For A/T)
(2) Steering Wheel (9) Steering Column Assembly
(3) Steering Column Cover (10) Second Steering Shaft
(4) Combination Switch and SRS Coil Assembly (11) Instrument Panel Lower Cover
(5) Snap Ring (12) Driver Knee Bolster (reinforcement)
(6) Cushion Rubber
Removal 4. Disconnect the yellow 2-way SRS connector located

are pointing straight ahead. CAUTION: The wheel of the vehicle must be straight
ahead and the steering column in the “LOCK”
2. Turn the ignition switch to “LOCK”. position before disconnecting the steering column
3. Disconnect the battery “–” terminal cable, and wait at from the steering gear. Failure to do so will cause the
least 5 minutes. SRS coil assembly to become uncentered which will
cause damage to the SRS coil assembly.
5. Remove the engine hood opening lever, then remove 10. Apply a setting mark (1) across the steering wheel
instrument panel lower cover. and shaft so parts can be reassembled in their original
6. Remove driver knee bolster (reinforcement). position. Move the front wheels to the straight ahead
position, then use steering wheel remover J–29752
to remove the steering wheel.
430RW021
827RW070
8. Disconnect the yellow 2-way SRS connector and

horn lead located behind the inflator module.
WARNING: THE INFLATOR MODULE SHOULD
ALWAYS BE CARRIED WITH THE TRIM COVER
AWAY FROM YOUR BODY AND SHOULD ALWAYS
430RX005

coil.
827RW072
NOTE: SRS coil is a part of combination switch Insepction
assembly, which can not be replaced singly. Therefore,
be sure not to remove the SRS coil from the combination If the abnormal conditions are found through inspection,
switch assembly. replace the steering column assembly.
Column Capsule
Check capsules on steering column bracket assembly; all
must be securely seated in bracket slots and checked for
any loose conditions when pushed or pulled by hand.
825RW288

15. Remove cushion rubber.
16. Remove shift lock cable (For A/T).
431RW030
17. Disconnect the starter switch harness connector Check clearance between capsule and bracket. If must
located under the steering column, then remove lock be within 1mm (0.039 in).
cylinder assembly.
18. Apply a setting mark (1) across the universal joint and
second steering shaft to reassemble the parts in their
original position, then remove steering column
assembly and second shaft.
NOTE: A setting mark can be easily made if the shaft is
withdrawn a little by loosening the steering shaft universal
joint.
431RW031
431RW009
Column Tube Shaft Length
Check for collapes by measuring the distance as shown in Check the shaft length from the upper end of the slide joint
the figure. to the end of the shaft. If column length is not in
Standard distance: 162.2-165.8 mm (6.386-6.528 specifications, steering column should be replaced.
in) Standard length:
NON TILT TYPE: 912.4 – 914.4 mm
(35.921 – 36.000 in)
TILT TYPE: 664.2 – 666.2 mm (26.149 – 26.228 in)
431RY00005
Legend
(1) NON TILT TYPE
(2) TILT TYPE 431RY00007
Legend
Column Universal Joint for Tilt Mechanism (1) NON TILT TYPE
(2) TILT TYPE
If the resistance is felt when checked by rotate the joint,
Shaft Universal Joint (Lower End)
Sheared Injected Plastic Pin
If the resistance is felt when checked by rotate the joint,
Check the sheared injected plastic pins for any loose replace the steering column assembly.
conditions or damage.
431RY00006
Legend
(1) NON TILT TYPE
(2) TILT TYPE
Shaft Bellows Pipe CAUTION: When turning the SRS coil counter
Check the shaft bellows pipe for bend by using straight clockwise to full, stop turning if resistance is felt.
Forced further turning may damage to the cable in
edge. Measure the clearance between the bellows pipe
the SRS coil.
and the straight edge (at center of the bellows pipe).
Standard: Less than 1mm (0.039 in)
825RW016

431RW035 route each wire harness as illustrated so that the
harnesses do not catch any moving parts.
Tilt Mechanism
Tilt mechanism should moves smoothly.
While locked the tilt mechanism, be sure the steering
column latch securely by pushing the steering wheel
upward and downward.
Installation
1. Install steering column assembly and second
steering shaft.
2. Align the setting marks on the universal joint and
second steering shaft made during removal.
3. Tighten the steering column fixing bolt (dash panel) to
4. Tighten the steering column fixing nuts (cross beam)
825RW017
Legend
6. Install lock cylinder assembly. (2) Starter Switch Harness
7. Install shift lock cable (For A/T). (3) Combination Switch Harness
8. Install cushion rubber. (4) Inflator Module Harness
10. Install combination switch and SRS coil assembly. 13. Install steering wheel and align the setting marks
After installation of combination switch assembly, made when removing.
connect the combination switch wiring harness CAUTION: Never apply force to the steering wheel
connector and the SRS 2-way connector located in direction of the shaft by using a hammer or other
under the steering column. impact tools in an attempt to remove the steering
11. Turn the SRS coil counter clockwise to full, return wheel. The steering shaft is designed as an energy
about 3 turns and align the neutral mark. absorbing unit.
torque.
connector and horn lead, then install inflator module.
being pinched.
18. Install instrument panel lower cover.
19. Install the engine hood opening lever.
20. Connect the yellow 2-way SRS connector and horn
lead located under the steering column.
System Inspection
Turn the ignition switch to “ON” while watching warning
light.
Supplemental Restraint System Steering Wheel & Column and

Associated Parts
430RY00002
Special Tools
TOOL NO.
ILLUSTRATION
TOOL NAME
J–29752
Steering wheel remover
FRONT SUSPENSION 3C–1
RODEO
SUSPENSION
CONTENTS
Front Suspension . . . . . . . . . . . . . . . . . . . . . . . 3C–1
Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . 3D–1
Wheel and Tire System . . . . . . . . . . . . . . . . . . 3E–1
FRONT SUSPENSION
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 3C–1 Upper Control Arm . . . . . . . . . . . . . . . . . . . . . . 3C–13
General Description . . . . . . . . . . . . . . . . . . . . . 3C–2 Upper Control Arm and Associated Parts . 3C–13
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C–2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C–13
Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . 3C–5 Inspection and Repair . . . . . . . . . . . . . . . . . . 3C–14
Shock Absorber and Associated Parts . . . . 3C–5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C–14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C–5 Lower Control Arm . . . . . . . . . . . . . . . . . . . . . . 3C–16
Inspection and Repair . . . . . . . . . . . . . . . . . . 3C–5 Lower Control Arm and Associated Parts . 3C–16
Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C–6 Inspection and Repair . . . . . . . . . . . . . . . . . . 3C–17
Stabilizer Bar and Associated Parts . . . . . . 3C–6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C–18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C–6 Upper Ball Joint . . . . . . . . . . . . . . . . . . . . . . . . . 3C–19
Inspection and Repair . . . . . . . . . . . . . . . . . . 3C–6 Upper Ball Joint and Associated Parts . . . . 3C–19
Torsion Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C–7 Inspection and Repair . . . . . . . . . . . . . . . . . . 3C–20
Torsion Bar and Associated Parts . . . . . . . . 3C–7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C–20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C–7 Lower Ball Joint . . . . . . . . . . . . . . . . . . . . . . . . . 3C–21
Inspection and Repair . . . . . . . . . . . . . . . . . . 3C–8 Lower Ball Joint and Associated Parts . . . . 3C–21
Knuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C–10 Inspection and Repair . . . . . . . . . . . . . . . . . . 3C–22
Knuckle and Associated Parts . . . . . . . . . . . 3C–10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C–22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C–10 Main Data and Specifications . . . . . . . . . . . . . 3C–23
Inspection and Repair . . . . . . . . . . . . . . . . . . 3C–11 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C–24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C–11

systems.
3C–2 FRONT SUSPENSION
General Description each shock absorber is attached to the lower control arm.
The upper portion of each shock absorber extends
The front suspension is designed to allow each wheel to through a frame bracket and is secured with two rubber
compensate for changes in the road surface level without bushings, two retainers and a nut.
greatly affecting the opposite wheel. Each wheel is Ball joint assemblies are bolted to the outer end of the
independently connected to the frame by a steering upper and lower control arm and are attached to the
knuckle, ball joint assemblies, and upper and lower steering knuckle.
control arms. The front wheels are held in proper The inner ends of the upper control arm have pressed in
relationship to each other by two tie-rods which are bushings. Bolts, passing through the bushing, attach the
connected to steering arms on the knuckles, and to a control arm to the frame. The inner ends of the lower
steering unit. control arm are attached to the frame by bolts passing
All models have a front suspension system consisting of through the bushings.
control arms, stabilizer bar, shock absorber and a torsion Side roll of the front suspension is controlled by a spring
bar. The front end of the torsion bar is attached to the steel stabilizer bar. It is mounted in rubber bushings,
lower control arm. The rear of the torsion bar is mounted which are held to the frame by brackets. The ends of the
into a height control arm at the crossmember. Vehicle trim stabilizer bar are connected to the lower control arms by
height is controlled by adjusting this arm. links.
Shock absorbers are mounted between the brackets on
the frame and the lower control arms. The lower portion of
Diagnosis
defective.

wheel.
defective.
operation. section.
universal joint.
Tires not adequately inflated. Adjust pressure.

bushing.
required.
bearings.
pressure.
bushings.
bushings.
mounting.
Shock Absorber
450RW009

(1) Nut (4) Shock Absorber
(2) Rubber Bushing and Washer (5) Rubber Bushing and Washer
1. Raise the vehicle and support it with suitable safety 1. Install rubber bushing and washer.
stands. 2. Install shock absorber.
2. Remove wheel and tire assembly. Refer to Wheel 3. Install rubber bushing and washer.
4. Remove nut.
5. Install bolt and nut, then tighten to the specified
torque.
6. Remove shock absorber.

Check the following parts :
D Shock absorber
D Rubber bushing
Stabilizer Bar
410RW007
Legend (3) Link

(1) Rubber Bushing (4) Nut
(2) Bracket (5) Stabilizer Bar
Removal D Stabilizer bar

D Rubber bushing
safety stands. D Link ball joint
3. Remove wheel and tire assembly. Refer to Wheel Installation
Replacement in this section. 1. Install rubber bushing.
4. Remove nut. 2. Install stabilizer bar.
CAUTION: Be careful not to break the ball joint boot. 3. Install bracket, then tighten it to the specified torque.
5. Remove link.
4. Install link.
6. Remove bracket.
7. Remove stabilizer bar.
8. Remove rubber bushing. Torque: 50 N·m (37 lb ft)

Check the following parts :
Torsion Bar
Torsion Bar and Associated Parts
410RS003
Legend (2) Height Control Arm

(1) Adjust Bolt, End Piece and Seat (3) Torsion Bar
Removal
safety stands.
2. Apply the setting marks(1) to the adjust bolt and end
piece, then remove adjust bolt, end piece and seat.
410RS004
3. Apply the setting marks(2) to the height control arm Installation
and torsion bar, then remove height control arm.
1. Apply grease to the serrated portions, then install
torsion bar. Make sure the bars are on their correct
respective sides and align the setting marks(3).
410RS005
4. Apply the setting marks(3) to the torsion bar and

lower control arm, then remove torsion bar.
410RS007
410RS006
410RS006

D Torsion bar
D Height control arm
D Adjust bolt
D Rubber seat
2. Apply grease to the portion that fits into the bracket 4. Apply grease to the serrated portions.
then install height control arm and align the setting 5. Install adjust bolt and seat, then turn the adjust bolt to
marks(2). the setting mark(1) applied during disassembly.
410RS005
3. Apply grease to the bolt portion of the end piece(4).

Apply grease to the portion of the seat(5) that fits into
the bracket. 410RS004
410RS008
Knuckle
Knuckle and Associated Parts
410RW006

(1) Torsion Bar (7) Thrust Washer
(2) Lower Ball Joint (8) Oil Seal
(3) Back Plate (9) Upper Ball Joint
(4) Knuckle Assembly (10) Wheel Speed Sensor
(5) Knuckle
Removal 4. Remove the hub assembly. Refer to Front Hub and

Disk in this section.
1. Raise the vehicle and support the frame with suitable 5. Remove tie–rod end from the knuckle. Refer to Power
safety stands. Steering Unit in Steering section.
2. Remove wheel and tire assembly. Refer to Wheel in 6. Remove the speed sensor from the knuckle.
this section.
7. Loosen torsion bar by height control arm adjust bolt,
3. Remove the brake caliper. Refer to Disc Brakes in then remove torsion bar. Refer to Torsion Bar in this
Brake section. section.
8. Remove wheel speed sensor.
9. Remove back plate. 15. Remove needle bearing by using remover J–23907
10. Remove lower ball joint by using remover J–29107. (Except 2WD model).
boot.
901RW044
901RW163
11. Remove upper ball joint by using remover J–36831. Make necessary correction or parts replacement if wear,
boot.
D Knuckle
D Knuckle arm
D Needle bearing
D Thrust washer
Installation
1. Apply appropriate amount of multipurpose type
grease to the new bearing (Approx. 5 g) and install
needle bearing by using installer J–36838 and
J–8092 (Except 2WD model).
901RW162
12. Remove knuckle assembly.

13. Remove oil seal (Except 2WD model).
14. Remove washer (Except 2WD model).
901RW045
2. Apply multipurpose type grease to the thrust washer,
and install washer with chamfered side facing knuckle
(Except 2WD model).
3. Use a new oil seal, and apply multipurpose type
grease to the area surrounded by the lip (approx. 2 g).
Then use installer J–36837 and J–8092 to install oil
seal. After fitting the oil seal to the installer, drive it to
the knuckle using a hammer or bench press until the
tool front face contacts with the thrust washer (Except
2WD model).
901RW167
4. Install knuckle assembly.

5. Install upper ball joint and tighten the nut to the
6. Install lower ball joint and tighten the nut to the
8. Install wheel speed sensor.
9. Install torsion bar, refer to Torsion Bar in this section.
Alignment Inspection and Adjustment in Steering.
Upper Control Arm

Upper Control Arm and Associated Parts
450RW005
Legend (7) Bushing

(1) Bolt and Plate (8) Plate
(2) Camber Shims (9) Nut
(3) Caster Shims (10) Speed Sensor Cable
(4) Nut Assembly (11) Nut and Cotter Pin
(5) Upper Control Arm Assembly (12) Upper Ball Joint
(6) Fulcrum Pin
Removal 3. Remove the brake caliper and disconnect brake pipe.

Refer to Disc Brakes in Brake section.
1. Raise the vehicle and support the frame with suitable 4. Support lower control arm with a jack.
safety stands.
5. Remove speed sensor cable.
2. Remove wheel and tire assembly. Refer to Wheel in
this section. 6. Remove nut and cotter pin then use remover
J–36831.
boot.
901RW160
16. Remove fulcrum pin.

901RW162
7. Remove upper ball joint. Inspection and Repair

8. Remove bolt and plate. Make necessary parts replacement if wear, damage,
9. Remove nut assembly. corrosion or any other abnormal conditions are found
10. Remove camber shims and note the positions and through inspection.
number of shims. Check the following parts:
11. Remove caster shims and note the positions and D Upper control arm
number of shims. D Bushing
12. Remove upper control arm assembly. D Fulcrum pin
13. Remove nut.
14. Remove plate. Installation
15. Remove bushing by using remover J–29755.
1. Install fulcrum pin.
2. Install bushing by using installer J–29755 and
J–39376.
901RW161
901RW164
901RW159 450RS013
3. Install plate. Legend

4. Install nut and tighten fulcrum pin nut finger–tight. (1) Projection
NOTE: Torque fulcrum pin nut after adjusting buffer (2) Outward
clearance.
Buffer clearance: 22 mm (0.87 in) 6. Install the caster shims(2) between the chassis frame
and fulcrum pin.
7. Install the camber shims(1) between the chassis
frame and fulcrum pin.
450RS012
5. Install upper control arm assembly with the fulcrum

pin projections turned inward. 450RS014
8. Install nut assembly.

9. Install bolt and plate, then tighten the bolt to the
specified torque.
10. Install upper ball joint and tighten it to the specified
torque.
11. Install nut and cotter pin then tighten the nut to the
Lower Control Arm

Lower Control Arm and Associated Parts
450RW010
Legend (8) Bolt, Torsion Bar Arm

(1) Nut, Front (9) Torsion Bar Arm Bracket
(2) Bush, Front (10) Torsion Bar
(3) Bolt, Front (11) Lower Control Arm
(4) Nut, Rear (12) Lower Ball Joint
(5) Bush, Rear (13) Shock Absorber
(6) Bolt, Rear (14) Stabilizer Link
(7) Bolt, Lower Ball Joint
Removal 3. Remove the tie-rod end from the knuckle. Refer to

Power Steering Unit in Steering section.
1. Raise the vehicle and support the frame with suitable 4. Remove the retaining ring from the front axle driving
safety stands. shaft to release the shaft from hub(Except 2WD
2. Remove wheel and tire assembly. Refer to Wheel in model). Refer to Front Hub and Disc in Driveline/Axle
this section. section.
6. Remove front nut. 19. Remove rear bushing by using remover J–36834.
7. Remove rear nut.
8. Remove torsion bar, refer to Torsion Bar in this
section.
9. Remove torsion bar arm bracket.
10. Disconnect the stabilizer link at the lower control arm.
11. Remove the shock absorber lower end from the lower
control arm.
12. Remove the lower ball joint from the lower control
arm.
13. Remove front bolt.
14. Remove rear bolt.
15. Remove lower control arm.
16. Remove torsion bar arm bolt.
17. Remove lower ball joint bolt.
18. Remove front bushing by using remover J–36833.
901RW051
901RW154
901RW052

D Lower control arm
D Bushing
901RW155
Installation 11. Install torsion bar arm bracket and tighten it to the
specified torque.
1. Install rear bushing by using installer J–36834.
12. Install Torsion bar, refer to Torsion Bar in this section.
13. Install rear nut and tighten lower link nut finger–tight.
clearance.
901RW053
2. Install front bushing by using installer J–36833.
450RS012
14. Install front nut then tighten lower link nut finger-tight.
clearance .
901RW156
3. Install lower ball joint bolt.

4. Install torsion bar arm bolt.
5. Install lower control arm.
6. Install rear bolt.
7. Install front bolt.
8. Install lower ball joint and tighten it to the specified
torque.
9. Install shock absorber and tighten it to the specified
torque.
10. Install stabilizer link and tighten it to the specified
torque. 450RS012

Upper Ball Joint

Upper Ball Joint and Associated Parts
450RW004
Legend (2) Upper Ball Joint

(1) Bolt and Nut (3) Nut and Cotter Pin
Removal
safety stands.
2. Remove the speed sensor from the knuckle.
3. Remove upper ball joint nut and cotter pin, then use D After moving the ball joint 4 or 5 times, attach nut then
remover J–36831 to remove the upper ball joint from measure the preload.
the knuckle. Starting torque: 0.5 –3.2 N·m (0.4–2.4 lb ft)
boot.
450RS024
If the above limits specified are exceeded, replace the ball

901RW162 joint assembly.
5. Remove upper ball joint. Installation
1. Install upper ball joint.
Inspection and Repair 2. Install bolt and nut, then tighten them to the specified
Make necessary parts replacement if wear, damage, torque.
corrosion or any other abnormal conditions are found Torque: 57 N·m (42 lb ft)
through inspection.
D Inspect the lower end boot for damage or grease leak. 3. Install nut and cotter pin, then tighten the nut to the
Move the ball joint as shown in the figure to confirm its specified torque with just enough additional torque to
normal movement. align cotter pin holes. Install new cotter pin.
D Inspect screw/taper area of ball for damage. Torque: 98 N·m (72 lb ft)
450RS023
Lower Ball Joint

Lower Ball Joint and Associated Parts
450RW011
Legend (3) Nut

(1) Bolt (4) Nut and Cotter Pin
(2) Lower Ball Joint
Removal
safety stands.
2. Remove wheel and tire assembly. Refer to Wheel in
this section.
3. Remove the tie-rod end from the knuckle. Refer to
Power Steering Unit in Steering section.
4. Remove the retaining ring from the front axle driving
shaft to release the shaft from hub(Except 2WD
model). Refer to Front Hub and Disc in Driveline/Axle
section.
6. Remove lower ball joint nut and cotter pin, then use
remover J–29107 to remove the lower ball joint from
the knuckle.
boot.
901RW163
7. Remove nut. Installation
8. Remove bolt.
1. Install lower ball joint.
9. Remove lower ball joint.
2. Install bolt.
3. Install nut and tighten it to the specified torque.
Make necessary parts replacement if wear, damage,
corrosion or any other abnormal condition are found 4. Install ball joint nut, then tighten it to the specified
through inspection. torque with just enough additional torque to align
cotter pin holes. Install new cotter pin.
Move the ball joint as shown in the figure to confirm its Torque: 147 N·m (108 lb ft)
normal movement .
450RS026
D After moving the ball joint 4 or 5 times, attach nut the

measure the preload.
Starting torque: 0.5–6.4 N·m (0.4–4.7 lb ft)
450RS024
D If the above limits specified are exceeded, replace the

ball joint assembly.

Front suspension Type Independent wishbone arms, torsion bar spring
with stabilizer bar.
Torsion bar spring Length 1142 mm (45.0 in)
Diameter 28.0 mm (1.10 in)
Front shock absorber Type Hydraulic, double acting, telescopic
Stroke 125.0 mm (4.92 in)
Compressed length 255.0 mm (10.04 in)
Extended length 380.0 mm (14.96 in)
Stabilizer bar Diameter 24.0 mm (0.94 in)
E03RX001
Special Tools
TOOL NO. TOOL NO.
TOOL NAME TOOL NAME
J–36833
J–23907
Remover;Needle
kit;
bearing
Lower arm front bushing
J–36834
J–36838 Remover and Installer
Installer; Needle bearing kit;
Lower arm rear bushing
J–8092 J–36831
Grip Ball joint remover
J–36837 J–29107
Installer; Oil seal Tie-rod end remover
J–39376
Installer; Upper arm
bushing
J–29775
Upper arm bushing
RODEO
SUSPENSION
REAR SUSPENSION
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 3D–1 Upper Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–10
General Description . . . . . . . . . . . . . . . . . . . . . 3D–1 Upper Link and Associated Parts . . . . . . . . 3D–10
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–10
Coil Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–5 Inspection and Repair . . . . . . . . . . . . . . . . . . 3D–10
Coil Spring and Associated Parts . . . . . . . . 3D–5 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–5 Lateral Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–12
Inspection and Repair . . . . . . . . . . . . . . . . . . 3D–6 Lateral Rod and Associated Parts . . . . . . . 3D–12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–12
Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . 3D–7 Inspection and Repair . . . . . . . . . . . . . . . . . . 3D–12
Shock Absorber and Associated Parts . . . . 3D–7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–7 Stabilizer Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–14
Inspection and Repair . . . . . . . . . . . . . . . . . . 3D–7 Stabilizer Bar and Associated Parts . . . . . . 3D–14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–14
Trailing Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–8 Inspection and Repair . . . . . . . . . . . . . . . . . . 3D–14
Trailing Link and Associated Parts . . . . . . . 3D–8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–8 Main Data and Specifications . . . . . . . . . . . . . 3D–16
Inspection and Repair . . . . . . . . . . . . . . . . . . 3D–8 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D–9

The rear suspension is a 5-link, coil spring type
suspension with a stabilizer bar, consisting of two trailing
links, two upper links, lateral rod, shock absorber, and
stabilizer. In this suspension, the links are specially
arranged to enable the rear axle to move freely, thereby
expanding suspension stroke, reducing friction, and
improving lateral rigidity and roll control. All these result in
improved stability, riding comfort, and rough road
maneuverability.
Each link connects the axle housing with the frame
through a runner bushing. The axle housing is supported
by the trailing links and upper links longitudinally and by
the lateral rod latitudinally.
systems.
Diagnosis
defective.
wheel.
defective.

operation. section.
universal joint.
bushing.
required.
bearings.
pressure.
bushings.

bushings.
mounting.
Coil Spring
Coil Spring and Associated Parts
460RW003
Legend (4) Coil Spring

(1) Stabilizer Bar (5) Insulator
(2) Upper Link Fixing Bolt and Nut (6) Shock Absorbar
(3) Rubber Plate (7) Breather Hose
Removal 6. Disconnect the stabilizer bar at the stabilizer link.

7. Remove the shock absorber from the axle case.
safety stands. 8. Remove spring insulator.
2. Support the rear axle case with a jack. 9. Remove the insulator and coil spring while lowering
the rear axle case.
3. Disconnect brake hose at the crossmember.
4. Remove breather hose. CAUTION: Be sure not to let the brake hose, parking
brake cable, and breather hose extend to their full
5. Remove upper link fixing bolt, nut and rubber plate on length.
the rear axle case (left-side only).
Inspection and Repair 3. Install the insulator on the coil spring. Jack up the axle
case gently with the top of the coil spring set to the
Make necessary correction or parts replacement if wear, spring seat on the frame side.
D Coil spring
D Insulator
Installation
1. Install coil spring and make sure that the coil spring is
installed in the proper position. Paint mark(1) should
be downward.
460RW013
4. Install shock absorber and tighten the nut lightly, then

retighten it to the specified torque after the vehicle is
at curb height.
NOTE: When mounting shock absorber, be sure not to
460RW001 6. Install upper link with rubber plate and tighten fixing
2. Fit the end of the coil spring to the coil spring seat and bolt.
mount the coil spring on the rear axle case. Torque: 137 N·m (101 lb ft)
7. Install breather hose.
8. Connect brake hose and bleed the brake system.
Refer to Bleeding the Brake Hydraulic System in
Brake section.
460RW004
Shock Absorber
461RW001

(1) Nut, Bush and Washer (3) Nut and Washer
1. Remove shock absorber fixing nut, bush and washer 1. Install shock absorber. When mounting shock
(upper side). absorber, be sure not to use grease on bushings or
2. Remove shock absorber fixing nut and washer (lower any other nearby part.
side). 2. Install nut and washer (lower side), then tighten the
3. Remove shock absorber. nut lightly. Retighten to the bolt and nut specified
torque after the vehicle is at curb height.
3. Install nut, bush and washer (upper side), then tighten
the nut lightly. Retighten to the nut specified torque
after the vehicle is at curb height.
Check the following parts: Torque: 20 N·m (14 lb ft)
D Shock absorber
D Rubber bushing
Trailing Link
Trailing Link and Associated Parts
460RW005
Legend (2) Protector (Left side only)

(1) Bolt and Nut (Axle side) (3) Bolt (Frame side)
Removal
1. Remove the parking brake cable from the trailing link.
2. Remove the trailing link fixing bolt, nut and protector.
3. Remove trailing link.

1. Trailing link
2. Rubber bushing
J–39214.
901RW058
D Install the rubber bushing by using installer
J–39214.
901RW059
Installation
1. Install trailing link. Make sure that the trailing link is in
NOTE: When mounting trailing link, be sure not to use
grease on bushings or any other nearby part.
460RW011
2. Install bolt, nut and protector. Tighten the bolts and

nuts lightly, then retighten them to the specified
torque after the vehicle is at curb height.
3. Install parking brake cable.
CAUTION: The parking brake cable should not be
overstrained or slackened.
Upper Link
Upper Link and Associated Parts
460RW006
Legend (3) Upper Link

(1) Bolt and Nut (Axle side) (4) Protector (Left side only)
(2) Rubber Plate (5) Bolt (Frame side)
Removal
1. Remove fuel tank. Refer to Engine Fuel in Engine
section.
2. Remove the speed sensor cable from the upper link.
3. Remove bolt, nut, rubber plate and protector.
4. Remove upper link.

1. Upper link
2. Rubber bushing
J–43008.
460RY00006
D Install the rubber bushing by using to installer
J–43008.
460RY00007
Installation
1. Install upper link. Make sure that the upper link is in its
correct position.
NOTE: When mounting upper link, be sure not to use
grease bushings or any other nearby part.
460RW012
2. Install bolt, nut, rubber plate and protector. Tighten

the bolts and nuts lightly, then retighten them to the
specified torque after the vehicle is at curb height.
4. Install fuel tank.
Lateral Rod
Lateral Rod and Associated Parts
460RW007
Legend (2) Lateral Rod

(1) Bolt and Nut (Frame side) (3) Nut and Washer (Axle side)
Removal
3. Remove lateral rod.

1. Lateral rod
2. Rubber bushing (Frame side)
D Remove the rubber bushing (Frame side) by using
remover J–39214.
901RW060
D Install the rubber bushing (Frame side) by using
Installer J–39215.
NOTE: When mounting rubber bushings, do not use
grease on bushings or any other nearby parts.
901RW063
Installation
1. Install lateral rod and make sure that the lateral rod is
901RW061 in its correct position.
3. Rubber bushing (Axle side) NOTE: When mounting lateral rod, be sure not to use
D Remove the rubber bushing (Axle side) by using grease on bushings or any other nearby part.
remover J–39792.
460RW008
901RW062
Legend
D Install the rubber bushing (Axle side) by using
installer J–39792. (1) Frame Side
(2) Axle Side
2. Install bolt and nut. Tighten the bolt and nut lightly,
3. Install nut and washer. Tighten the nut lightly, then
retighten the nut to the specified torque after the
Stabilizer Bar
460RW009

(1) Bracket (4) Stabilizer Bar
(2) Link (5) Rubber Bushing
Removal 6. Remove rubber bushing.

safety stands. Inspection and Repair
2. Remove wheel and tire assembly. Refer to Wheel in Make necessary correction or parts replacement if wear,
this section. damage, corrosion or any other abnormal condition are
3. Remove bolt and nut. found through inspection.
4. Remove link.
D Stabilizer bar
CAUTION: Be careful not to damage the ball joint D Rubber bushing
boot.
D Link
5. Remove bracket.
Installation
1. Install rubber bushing.
2. Install bracket to axle housing and tighten to the
specified torque.
3. Install link.
4. Install bolt and nut, then tighten the nut to the
specified torque.
460RW010

Rear suspension Type 5–Link, coil spring type with stabilizer bar.
Coil spring Free length 389.5mm (15.33in)
Spring diameter 12.2mm (0.48in)
Coil diameter (inner) 105mm (4.13in)
Effective No. of turns 5.74
Total No. of turns 7.24
Shock absorber Type Hydraulic, double acting, telescopic
Piston diameter 30mm (1.18in)
Stroke 175mm (6.89in)
Extended length 473.5mm (18.64in)
Compressed length 298.5mm (11.75in)
Stabilizer bar Diameter 18mm (0.71in)
E03RW003
Special Tools
TOOL NO.
ILLUSTRATION
TOOL NAME
J–39214
Trailing link bushing
J–43008
Upper link bushing
J–39792
Lateral rod bushing (axle
side)
J–39215
Lateral rod bushing
RODEO
SUSPENSION
WHEEL AND TIRE SYSTEM
CONTENTS
Service Precaution . . . . . . . . . . . . . . . . . . . . . . 3E–1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E–11
General Description . . . . . . . . . . . . . . . . . . . . . 3E–2 Tire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E–12
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E–3 Tire Replacement . . . . . . . . . . . . . . . . . . . . . . 3E–12
Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E–11 General Balance Procedure . . . . . . . . . . . . . . 3E–12
Wheel and Associated Parts . . . . . . . . . . . . 3E–11 Balancing Wheel and Tire . . . . . . . . . . . . . . . . 3E–13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E–11 Main Data and Specifications . . . . . . . . . . . . . 3E–14

systems.
General Description
480RS008
Replacement wheels or tires must be equivalent to the

originals in load capacity, specified dimension and
mounting configuration. Improper size or type may affect
bearing life, brake performance, speedometer/odometer
calibration, vehicle ground clearance and tire clearance
to the body and chassis. All model are equipped with
metric sized tubeless steel belted radial tires. Correct tire
pressures and driving habits have an important influence
on tire life. Heavy cornering, excessively rapid
acceleration and unnecessary sharp braking increase
premature and uneven wear.
Diagnosis
defective.
wheel.
defective.

operation. section.
universal joint.
bushing.
required.
bearings.
pressure.
bushings.

bushings.
mounting.
Irregular and Premature Wear
480RS001
Irregular and/or premature wear has many causes. NOTE: Due to their design, radial tires tend to wear faster
Some of them are incorrect inflation pressures, lack of tire in the shoulder area, particularly on the front tires. This
rotation, poor driving habits or improper wheel alignment. makes regular rotation especially necessary. After
Incorrect inflation is common cause of tire premature rotation, be sure to check wheel nut torque, and set tire
wear. pressures.
Tire Rotation indicators may appear as wide bands. When the indica-
Tire rotation is recommended to equalize wear for longer tors appear in two or more grooves at three locations, tire
tire life. replacement is recommended.
Inflation of Tires
480RS002
Legend 710RW002
(1) Spare Tire Tire pressure, in cold condition (after vehicle has set for
three hours or more, and driven less than one mile),
If the following conditions are noted, rotate the tires: should be checked monthly or before any extended trip.
D Front tire wear is different from rear. Tire pressure increases approximately 15% when the
D Uneven wear exists across the tread of any tire. tires become hot during driving. Tire pressure specifica-
D Left and right front tire wear is unequal. tion is shown on the label located on the left door lock pil-
lar.
D Left and right rear tire wear is unequal.
Check wheel alignment if the following conditions are NOTE: Check the tire pressure whenever irregular wear
noted: is found. Tire inflation greatly affects tire wear. If the
alignment check does not reveal any alignment problems,
D Left and right front tire wear is unequal. check the condition of the shock absorbers and wheel/tire
D Wear is uneven across the tread of any front tire. balance.
D Front tire treads have a scuffed appearance with
“feather” edges on one side of the tread ribs or blocks. Diagnosis List
If the following conditions are noted, rotation is required.
Tread Wear Indicators 1. Front tire wear is different from rear.
2. Uneven wear exists across the tread of any tire.
3. Left and right front tire wear is unequal.
4. Left and right rear tire wear is unequal.
If the following conditions are noted, check the wheel
alignment.
1. Left and right front tire wear is unequal.
2. Uneven wear exists across the tread of any tire.
3. Front tire treads have scuffed appearance with
“feather” edges on one side of tread ribs or blocks.
4. There is cupping, flat spotting etc.
Higher than recommended pressure can cause:
1. Hard ride.
2. Poor steering stability.
3. Rapid and uneven wear at center of the tread.
Lower than recommended pressure can cause:
1. Tire squeal on turns.
2. Hard steering.
480RS006
The original equipment tires have built-in tread wear indi- 3. Rapid and uneven wear on the edges of the tread.
cators(1) to show when tires need replacement. These 4. Tire rim bruises and rupture.

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2000

Arrow Type Application Arrow Type Application

D Gas other than

D Ambient air mixed

View Detall Motion or direction

Lubrication point oil or

Dimension (1:2) Lubrication point grease

Sectioning (1:3) Lubrication point jelly

Transmission Serial Number

Theft Prevention Standard

0A-11 TRANSMISSION 2– Manual transmission V.I.N. plate

0A-11 BODY 3– Engine hood V.I.N. label

Anti Theft Stamping/Plate/Label

Manual Transmission (AR–5)

Legend (6) Fender

Legend (10) Back Door Right Side

Precautions in pulling off the masking tape

Supportable Point; Front Supportable Point; Rear

Standard Bolts Torque Specifications

The asterisk * indicates that the bolts are used for

Abbreviations Charts Exh — Exhaust

Maintenance Schedule List Severe Driving Conditions

Mileage Only Items

Explanation of Complete Vehicle Valve Clearance Adjustment

Accelerator Linkage Lubrication

Steering and Suspension Inspection

Body and Chassis Lubrication

Propeller Shaft Inspection and Lubrication

Auto Cruise Control Inspection

Clutch Lines and Hoses Inspection

Clutch Control Lubrication

Clutch Pedal Free Play Inspection

Accelerator Linkage Inspection

Recommended Fluids and Lubricants

Lubricant Viscosity Chart

Oil Viscosity Chart for Gasoline Engine

Oil Viscosity Chart for Manual Transmission and Transfer Case

Oil Viscosity Chart for Front Axle

Recommended Liquid Gasket

Recommended Thread Locking

3. Tighten the bolts to the specified torque.

Maintenance Service Data

* Unless otherwise specified on tire information label on the vehicle.

HEATING, VENTILATION AND AIR

Service Precaution CAUTION: Always use the correct fastener in the

Heating and Ventilation System

Legend (8) Duct

Legend (3) Fan Control Knob (Fan Switch)

Air Source Select Lever Temperature Control Knob

Condition Possible cause Correction

Chart “A” Blower Motor Dose Not Run

Chart “B” Blower Motor Does Not Run At Low Position

Chart “E” Blower Motor Dose Not Run At High Position

Individual Inspection Resistor

Fan switch Resistor terminals

Fan Control Knob (Fan Switch)

2. Check for continuity between the heater and the A/C

Fan switch Switch connector terminals with con-

4 1–4–6 Relay terminals with

Heater & A/C Relay Normal 1 – 3 (Approx 85–105W)