Isuzu 2000 Trooper UX Workshop Manual Download Page 1 | Manualshive

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WORKSHOP MANUAL

TROOPER

(UX)

FOREWORD

This manual includes special notes, important points, service
data, precautions, etc. that are needed for the maintenance,
adjustments, service, removal and installation of vehicle
components.

All information, illustrations and specifications contained in
this manual are based on the latest product information
available at the time of publication.

All rights are reserved to make changes at any time without
notice.

Arrangement of the material is shown in the table of contents
on the right-hand side of this page. A black spot on the first
page of each section can be seen on the edge of the book
below each section title. These point to a more detailed table
of contents preceding each section.

This manual applies to 2000 models.

SECTION

TABLE OF CONTENTS

GENERAL INFORMATION

0A

General Information

0B

Maintenance and Lubrication

HEATING, VENTILATION AND AIR CONDITIONING

1A

HVAC Systems

STEERING

2A

Power Assisted System

SUSPENSION

3C

Front Suspension

3D

Rear Suspension

3E

Wheel and Tire System

DRIVELINE/AXLE

4A1

Differential (Front)

4A2

Differential (Rear)

4B1

Driveline Control System (SHIFT ON THE FLY)

4B2

Driveline Control System (TOD)

4C

Drive Shaft System

4D1

Transfer Case (Standard Type)

4D2

Transfer Case (TOD)

BRAKE

5A

Brake Control System

5B

Anti-Lock Brake System

5C

Power-Assisted Brake System

5D

Parking Brake System

ENGINE

6A

Engine Mechanical

6B

Engine Cooling

6C

Engine Fuel

6D1

Engine Electrical

6D2

Ignition System

6D3

Starting and Charging System

6E

Driveability and Emissions

6F

Engine Exhaust

6G

Engine Lubrication

6H

Engine Speed Control System

6J

Induction

TRANSMISSION

7A

Automatic Transmission

7A1

Transmission Control System

7B

Manual Transmission

7C

Clutch

BODY AND ACCESSORIES

8A

Lighting System

8B

Wiper/Washer System

8C

Entertainment

8D

Wiring System

8E

Meter and Gauge

8F

Body Structure

8G

Seats

8H

Security and Locks

8I

Sun Roof/Convertible Top

8J

Exterior/Interior Trim

RESTRAINTS

9A

Seat Belt System

9J

Supplemental Restraint System (SRS)

9J1

Restraint Control System

CONTROL SYSTEM

10A

Cruise Control System

1
2
3
...
»

Summary of Contents for 2000 Trooper UX

Page 1: ...Assisted System SUSPENSION 3C Front Suspension 3D Rear Suspension 3E Wheel and Tire System DRIVELINE AXLE 4A1 Differential Front 4A2 Differential Rear 4B1 Driveline Control System SHIFT ON THE FLY 4B...

Page 2: ...f 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 ver...

Page 3: ...nt of vehicle Up Side Task Related View Detall View Angle Dimension 1 2 Sectioning 1 3 Arrow Type Application D Ambient Clean air flow D Cool air flow D Gas other than ambient air D Hot air flow D Amb...

Page 4: ...ication 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 t...

Page 5: ...left rear lower area of the cylinder block above the starter F06RW001 Transmission Serial Number Manual Stamped on the left side of the transmission intermediate plate 220RW084 Automatic Stamped on th...

Page 6: ...OT mark Reference COMPONENT INDICATION Figure No COMPONENT PRODUCTION SERVICE PARTS 0A 10 ENGINE 1 6VE1 V I N plate 0A 11 TRANSMISSION 2 Manual transmission Automatic transmission V I N plate 0A 11 BO...

Page 7: ...g 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...

Page 8: ...0A 7 GENERAL INFORMATION Automatic Transmission THM 901RW197 Body 901RW113 Legend 3 Engine Hood 4 Front Door 5 Rear Door 6 Fender 7 Rear Quarfer Panel 8 Front Bumper...

Page 9: ...0A 8 GENERAL INFORMATION Body 901RW114 Legend 9 Back Door Left Side 10 Back Door Right Side 11 Rear Bumper...

Page 10: ...nti 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 tap...

Page 11: ...nts 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 co...

Page 12: ...s stands at the bottom of the frame sidemember behind the front wheel 501RS003 Lifting Point Rear D Position the floor jack at the center of the rear axle case when lifting the vehicle 420RS002 Suppor...

Page 13: ...0A 12 GENERAL INFORMATION Supportable Point Rear D Position the chassis stands at the bottom of the rear axle case 420RS001...

Page 14: ...m 152 229 lb ft 251 414 N m 185 305 lb ft 359 539 N m 265 398 lb ft 5 10 N m 4 7 lb ft 12 23 N m 9 17 lb ft 28 46 N m 20 34 lb ft 28 45 N m 20 33 lb ft 61 91 N m 45 67 lb ft 57 84 N m 42 62 lb ft 93 1...

Page 15: ...e ECT Engine Coolant Temperature EEPROM Electronically Erasable Programmable Read Only Memory EGR Exhaust Gas Recirculation EI Electronic Ignition ETR Electronically Tuned Receiver EVAP Evaporation Em...

Page 16: ...on Speedo Speedometer SRS Supplemental Restraint System ST Start Scan Tool Sw Switch SWB Short Wheel Base SYN Synchronize Tach Tachometer TB Throttle Body TBI Throttle Body Fuel Injection TCC Torque C...

Page 17: ...on unleaded fuel Unusual or severe operating conditions will require more frequent vehicle maintenance as specified in the following sections Severe Driving Conditions If the vehicle is usually opera...

Page 18: ...0B 2 MAINTENANCE AND LUBRICATION Mileage Only Items...

Page 19: ...0B 3 MAINTENANCE AND LUBRICATION Mileage Months...

Page 20: ...0B 4 MAINTENANCE AND LUBRICATION...

Page 21: ...ve Clearance Adjustment Incorrect valve clearance will result in increased engine noise and reduced engine output Retorque the camshaft bearing cap bolts before checking and adjusting the valve cleara...

Page 22: ...r or a pull right or left on a straight and level road may show the need for a wheel alignment A vibration of the steering wheel or seat at normal highway speeds means a wheel balancing is needed Chec...

Page 23: ...eller 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 accelera...

Page 24: ...oper 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 Rele...

Page 25: ...art 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...

Page 26: ...0B 10 MAINTENANCE AND LUBRICATION Oil Viscosity Chart for Manual Transmission and Transfer Case B00RW002 Oil Viscosity Chart for Front Axle B00RW003...

Page 27: ...Isuzu Isuzu For Engine Repairs Anaerobic LOCTITE 515 LOCTITE 518 LOCTITE 17430 Loctite Loctite Loctite All RTV Room Temperature Vulcanizer NOTE 1 It is very important that the liquid gaskets listed ab...

Page 28: ...nd 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 torq...

Page 29: ...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 Ite...

Page 30: ...1A 24 Rear Heater Duct Defroster Nozzle Ventilation Duct and Associated Parts 1A 24 Removal 1A 24 Installation 1A 25 Center and or Drive Side Vent 1A 25 Center Vent Drive Side Vent and Associated Part...

Page 31: ...r Conditioning System 1A 81 General Description 1A 81 Full Automatic Air Conditioner Parts Configuration 1A 81 Refrigerant Line and Associated Parts 1A 82 Circuit Diagram 1A 83 Functions and Features...

Page 32: ...htening 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...

Page 33: ...nd 1 Side Defroster Hose 2 Vent Box 3 Upper Center Vent Box 4 Lower Center Vent Box 5 Blower Assembly 6 Control Lever Assembly 7 Evaporator Assembly 8 Duct 9 Heater Unit 10 Rear Heater Duct 11 Lap Ven...

Page 34: ...e of the heater unit and the mode door for the air source of the blower assembly The fan control is used to control the amount of air sent out by the resistor at four levels from LOW to HIGH 865RW007...

Page 35: ...AIR SOURCE SELECT LEVER to FRESH position and turn on the blower fan Heating can be done in this lever position sending in fresh air from outside The blower fan also serves to deliver fresh outside a...

Page 36: ...vered to the side windows Moving the air source select lever to the CIRC position provides quickest heat delivery by closing the blower assembly mode door In this position outside air is not delivered...

Page 37: ...1A 8 HEATING VENTILATION AND AIR CONDITIONING HVAC Wiring Diagram D01RS005...

Page 38: ...insufficient Check if the water hose to the heater core is clogged collapsed or twisted Repair or replace as necessary Heater core clogged or collapsed Clean or replace as necessary The heater cores...

Page 39: ...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 INS...

Page 40: ...ground No B 2 Open circuit between No C 19 25A fuse and No B5 1 Chart B Blower Motor Does Not Run At Low Position Step Action Yes No 1 Is resistor OK Go to Step 2 Replace 2 Is fan control knob Fan Swi...

Page 41: ...K 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 No I18 2 Replace control lever assembly Indivi...

Page 42: ...connector terminals with con tinuity OFF No continuity 1 1 2 4 2 1 4 5 3 1 3 4 4 1 4 6 Heater A C Relay 1 Disconnect the heater and the A C relay B 36 D When removing the connector for relay unfasten...

Page 43: ...Lower Duct 9 Driver Lap Vent Nozzle 10 Water Hose 11 Electro Thermo Connector With A C 12 Resistor Connector Removal 1 Disconnect the battery ground cable 2 Drain the engine coolant 3 Discharge and re...

Page 44: ...ove 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 con...

Page 45: ...ater Unit 5 Case Mode Control 6 Heater Core Removal 1 Disconnect the battery ground cable 2 Drain the engine coolant 3 Discharge and recover refrigerant with air conditioning D Refer to Refrigerant Re...

Page 46: ...emove heater core 1 860RS003 9 Pull out the mode door while raising up the catch of the door lever 860RS004 Inspection Check for foreign matter in the heater core stains or core fin damage Installatio...

Page 47: ...d cable 2 Drain engine coolant 3 Discharge and recover refrigerant with air conditioning D Refer to Refrigerant Recovery in this section 4 Remove heater unit D Refer to Heater Unit in this section 5 R...

Page 48: ...Removal 1 Disconnect the battery ground cable 2 Drain engine coolant 3 Discharge and recover refrigerant with air conditioning D Refer to Refrigerant Recovery in this section 4 Remove heater unit D R...

Page 49: ...ment Panel Assembly Removal 1 Disconnect the battery ground cable 2 Discharge and recover refrigerant with air conditioning D Refer to Refrigerant Recovery in this section 3 Remove instrument panel as...

Page 50: ...ntrol Lever Assembly in this section Blower Link Unit and or Mode door Disassembled View 873RS001 Legend 1 Upper Case 2 Mode Door 3 Lower Case 4 Sub Lever 5 Door Lever 6 Blower Assembly Removal 1 Disc...

Page 51: ...out the mode door while lifting up the catch of door lever 7 Remove sub lever 8 Remove door lever Installation To install follow the removal steps in the reverse order noting the following points 1 Ap...

Page 52: ...onnector 2 Blower Motor Assembly 3 Clip 4 Fan 5 Blower Motor 6 Attaching Screw Removal 1 Disconnect the battery ground cable 2 Remove blower motor connector 3 Remove attaching screw 4 Remove blower mo...

Page 53: ...eater Duct 8 Driver Lap Duct 9 Cross Beam Assembly 10 Instrument Panel Assembly Removal 1 Disconnect the battery ground cable 2 Remove instrument panel assembly D Refer to Instrument Panel Assembly in...

Page 54: ...mbly 3 Lower Cluster Assembly 4 Front Console Assembly 5 Instrument Panel Driver Lower Cover Assembly 6 Side Vent Removal 1 Disconnect the battery ground cable 2 Remove front console assembly 3 Remove...

Page 55: ...nnection 7 Attaching Screws 8 Control Lever Assembly 9 Mode Control Link Connection 10 Front Console Assembly 11 Lower Cluster Assembly 12 Instrument Panel Driver Lower Cover Assembly 13 Meter Cluster...

Page 56: ...5RS010 9 Pull the control lever assembly out and disconnect the fan switch and air conditioning switch connectors 865RS009 10 Remove control lever assembly 11 Remove control cable Installation To inst...

Page 57: ...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 cabl...

Page 58: ...Panel Passenger Lower Cover Assembly Removal 1 Disconnect the battery ground cable 2 Remove front console 3 Remove lower cluster 4 Remove glove box 5 Remove instrument panel passenger lower cover asse...

Page 59: ...ure Switch 8 Receiver Drier 9 Condenser 10 Compressor 11 Magnetic Clutch 12 Mode HEAT Control Door 13 Temp Control Door Air Mix Door 14 Heater Core 15 Mode VENT Control Door 16 Heater Unit 17 Mode DEF...

Page 60: ...the pressure That is the quantity of refrigerant liquid vaporized inside the evaporator is determined by the quantity of heat which must be removed at a prescribed vaporization temperature It is impo...

Page 61: ...lass 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 dri...

Page 62: ...istics of HFC 134a 874RY00003 Evaporator The evaporator cools and dehumidifies the air before the air enters the passenger compartment High pressure liquid refrigerant flows through the expansion valv...

Page 63: ...le 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 suc...

Page 64: ...ts 852RW009 Legend 1 Liquid Line High Pressure Pipe 2 O ring 3 Compressor 4 Discharge Line High Pressure Hose 5 Pressure Switch 6 Receiver Drier 7 Condenser Assembly 8 Drive Belt 9 Relay 10 Drain Hose...

Page 65: ...1A 36 HEATING VENTILATION AND AIR CONDITIONING HVAC Wiring Diagram D08RW254...

Page 66: ...HEATING VENTILATION AND AIR CONDITIONING HVAC 1A 37 D08RX003...

Page 67: ...1A 38 HEATING VENTILATION AND AIR CONDITIONING HVAC D08RW256...

Page 68: ...ant Discharge and recover the 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 refr...

Page 69: ...l 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 1...

Page 70: ...y High Insufficient cooling Excessive refrigerant in system Discharge and recover refrigerant Recharge to specified amount Discharge High Gauge Pressure Abnormally High High pressure gauge drop After...

Page 71: ...nt line connector is lower than around evaporator Expansion valve opens too long Replace the expansion valve Suction Low Gauge Pressure Abnormally High High and low pressure gauge balanced quickly Aft...

Page 72: ...d amount Insufficient cooling Condenser clogged or dirty Clean the condenser fins Suction Low Gauge and Discharge High Gauge Pressure Abnormally High Suction Low pressure hose Not cold Air in system E...

Page 73: ...NG HVAC Magnetic Clutch Diagnosis D08RX004 When the air conditioning switch and the fan control knob fan switch are turned on with the engine running current flows through the thermostat and the compr...

Page 74: ...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 Is there a continuity Magnetic clutch defective Compressor...

Page 75: ...nal No X5 1 Is there a battery voltage Go to Step 17 Go to Step 20 17 1 Reconnect thermostat relay 2 Check to see if battery voltage is present at chassis side connector terminal No B4 3 Is there a ba...

Page 76: ...continuity OFF No continuity 1 1 2 4 2 1 4 5 3 1 3 4 4 1 4 6 A C switch position A C switch connector terminals with continuity OFF 1 6 ON 1 2 6 Heater And A C B 36 Thermostat X 5 And Compressor X 7...

Page 77: ...gs 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 preve...

Page 78: ...he compressor model Be sure to apply oil specified for the model of compressor 850RW002 O rings 2 must be closely aligned with the raised portion 1 of refrigerant line 850RW003 Insert the nut into the...

Page 79: ...e the cooling unit Follow the method below when checking Remove the drain hose or resistor of the cooling unit and insert a leak detector to see if there occurs any leak High pressure side 1 Discharge...

Page 80: ...ld 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...

Page 81: ...s approximately 750 mmHg 30 inHg continue the evacuation for 5 minutes or more 6 Close both hand valves and stop the vacuum pump 7 Check to ensure that the pressure does not change after 10 minutes or...

Page 82: ...ssure 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 evacuat...

Page 83: ...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...

Page 84: ...sociated Parts 852RW010 Legend 1 Compressor Bracket 2 Seal Washer 3 Refrigerant Line Connector 4 Compressor 5 Drive Belt Removal 1 Disconnect the battery ground cable 2 Discharge and recover refrigera...

Page 85: ...ed 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...

Page 86: ...tor 7 Disconnect refrigerant line D When removing the line connector the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line 8 Remove conde...

Page 87: ...nnected part the connecting part should immediately be plugged or capped to prevent foreign matter from being mixed into the line 6 Remove bracket bolt 7 Remove receiver drier D Loosen the bolt then u...

Page 88: ...4 Disconnect pressure switch connector 5 Disconnect pressure switch D When removing the switch connected part the connecting part should immediately be plugged or capped to prevent foreign matter from...

Page 89: ...nsole Assembly 8 Lower Cluster Assembly 9 Evaporator Assembly Removal 1 Disconnect the battery ground cable 2 Discharge and recover refrigerant D Refer to Refrigerant Recovery in this section 3 Remove...

Page 90: ...cc 1 7 fl oz of new compressor oil to the new core 2 Tighten the refrigerant outlet line to the specified torque Torque 25 N m 18 lb ft 3 Tighten the refrigerant inlet line to the specified torque Tor...

Page 91: ...rator core 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 To insta...

Page 92: ...lining when assembling the evaporator assembly Air Conditioning Switch and Illumination Bulb Air Conditioning Switch Illumination Bulb and Associated Parts 865RS003 Legend 1 Control Lever Assembly 2 I...

Page 93: ...Disconnect the battery ground cable 2 Discharge and recover refrigerant D Refer to Refrigerant Recovery in this section 3 Remove radiator grille 4 Remove air cleaner 5 Remove clip and clamp 6 Disconn...

Page 94: ...om being mixed into the line Installation To install follow the removal steps in the reverse order noting the following points 1 O rings cannot be reused Always replace with new ones 2 Be sure to appl...

Page 95: ...nsion 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...

Page 96: ...HEATING VENTILATION AND AIR CONDITIONING HVAC 1A 67 Torque Specifications 852RW004 874RX016...

Page 97: ...ions can help you avoid damage to parts and systems General Description The HD6 HT6 Automotive Conditioning Compressor and Clutch Assembly is a light weight six cylinder axial design consisting of thr...

Page 98: ...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 th...

Page 99: ...3 2 mm 1 8 in out of the keyway The shaft key is curved slightly to provide an interference fit in the hub key groove 2 Be sure the frictional surface of the clutch plate and the clutch rotor 2 are c...

Page 100: ...g assembly retaining ring 2 using snap ring pliers 901RW003 3 Install pulley rotor and bearing puller guide J 33023 A to the front head and install J 41552 pulley rotor and bearing puller down into th...

Page 101: ...n 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...

Page 102: ...33026 to full fixture thickness 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...

Page 103: ...compressor must be drained measured recorded and replaced 871RW006 Legend 1 Suction Port 2 Discharge Port 3 Mounting Boss 4 Mounting Boss 5 Pressure Relief Valve 6 Mounting Boss Seal Leak Detection A...

Page 104: ...ide 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 an...

Page 105: ...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 o...

Page 106: ...r 50 cc 1 7 fl oz Condenser 30 cc 1 0 fl oz Receiver dryer 30 cc 1 0 fl oz Refrigerant line one piece 10 cc 0 3 fl oz Compressor Leak Testing External and Internal Bench Check Procedure 1 Install test...

Page 107: ...ng 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 disa...

Page 108: ...pressor Holding Fixture J 33023 A Puller Pilot J 41552 Pulley Puller J 33017 Pulley and Bearing Assembly Installer J 8433 1 Puller Bar ILLUSTRATION TOOL NO TOOL NAME J 8433 3 Forcing Screw J 33025 Clu...

Page 109: ...1A 80 HEATING VENTILATION AND AIR CONDITIONING HVAC ILLUSTRATION TOOL NO TOOL NAME J 34614 Shaft Seal Protector J 39893 Pressure Testing Connector...

Page 110: ...air quantity turn on or off the compressor and switch the blow port as well as switching between the fresh air intake and interior air circulation Resetting the automatic function allows you to switch...

Page 111: ...arts 852RY00002 Legend 1 Liquid Line High Pressure Pipe 2 O Ring 3 Discharge Line High Pressure Hose 4 Pressure Switch 5 Receiver Drier 6 Ambient Sensor 7 Condenser Assembly 8 Drive Belt 9 Compressor...

Page 112: ...HEATING VENTILATION AND AIR CONDITIONING HVAC 1A 83 Circuit Diagram 6VE1 Engine D08RY00109...

Page 113: ...1A 84 HEATING VENTILATION AND AIR CONDITIONING HVAC D08RY00110...

Page 114: ...HEATING VENTILATION AND AIR CONDITIONING HVAC 1A 85 D08RY00155...

Page 115: ...1A 86 HEATING VENTILATION AND AIR CONDITIONING HVAC D08RY00147...

Page 116: ...HEATING VENTILATION AND AIR CONDITIONING HVAC 1A 87 D08RY00148...

Page 117: ...re 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...

Page 118: ...HEATING VENTILATION AND AIR CONDITIONING HVAC 1A 89 Automatic Air Conditioner Block Diagram F01RY00006...

Page 119: ...NTILATION AND AIR CONDITIONING HVAC Control Panel Layout 865RY00024 Legend 1 Auto Switch 2 Mode Switch 3 DEF FOOT Switch 4 DEF Switch 5 Intake Switch 6 Fan Switch 7 Air Conditioning Switch 8 Temperatu...

Page 120: ...HVAC 1A 91 Air Control Functions C01RY00004 Legend 1 Interior Air Intake 2 Fresh Air Intake 3 Evaporator Core 4 Air Mix Door 5 DEF Door 6 VENT Door 7 FOOT Door 8 Sub Air Mix Door 9 Heater Unit 10 Heat...

Page 121: ...ature level Pressing the air conditioning switch in this state turns off the A C LED Mode Switch 1 Pressing the VENT B L or FOOT switch selects the corresponding mode 2 When the Auto is selected for t...

Page 122: ...n is turned on It may be used for the MAX control of each block except the fan 2 When the manual mode is selected for the fan control this manual mode is maintained MAX Control Mix Fan Mode Intake A C...

Page 123: ...and input signals from switches to offer total control of the blower fan and actuators used for the mode door intake door and air mix door Its self diagnosis function enables quicker access to a faile...

Page 124: ...Sensor It is a photodiode used for detecting quantity of solar radiation This sensor converts the offset signal generated by changes in the interior temperature which results from fluctuations in sola...

Page 125: ...ors are power driven type containing a small motor Receiving output current from the automatic heater air conditioner control unit actuators drive the heater and blower unit mode doors Actuators consi...

Page 126: ...oltage against the reference voltage VDD 5V then signals the value to the automatic heater air conditioner control unit C01RX016 Movement of Mix Actuator Position of the air mix door is determined by...

Page 127: ...e DEF to VENT direction C01RX017 Movement of Intake Actuator The controller on the automatic heater air conditioner control unit selects an intake mode to be used As the Terminal No 5 I 49 is grounded...

Page 128: ...e air mix door is accordingly fixed to the Full Heat or Full Cool mode When the VENT mode is selected aperture of the air mix door is controlled so that excessively heated air may not be blown from th...

Page 129: ...rating the DEF mode switch selects the DEF for the blow port mode C01RY00009 Intake Fresh air interior air switching Control In the Full Auto mode the automatic heater air conditioner control unit ope...

Page 130: ...s 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 coo...

Page 131: ...t is located this function restores its original performance When implementing the troubleshooting this self diagnosis function narrows the range to be searched at the first step then check relevant p...

Page 132: ...ply Diagnosis This check is required because a trouble on the auto amplifier control unit power supply circuit or grounding circuit prevents accurate troubleshooting D08RY00138 Condition Possible caus...

Page 133: ...ntinuity 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 Is the action complete...

Page 134: ...from LOW to HI 3 Blowing temperature chec k movement of the mode door Set temperature to 77 F Set the fan knob to HI Push the mode switch to change the blow port mode sequentially from the VENT throug...

Page 135: ...de D Intake mode D Fan speed MAX Hi D A C 1 Auto function FAN KNOB AUTO MODE SW AUTO Change the temperature gradually starting with 68 F up to 86 F The following phenomena shall be recognized D Temper...

Page 136: ...sor 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 Is the action complete Go...

Page 137: ...f the diagnosis along the following 9 items will be shown one by one in 0 5 second interval irrespective of presence or absence of a trouble for a given item When the display 9 items is completed it i...

Page 138: ...hile the current trouble diagnosis is taking place display of the past trouble diagnosis will appear on the indicator lamp LED of the air conditioning switch Results of the diagnosis along the followi...

Page 139: ...1A 110 HEATING VENTILATION AND AIR CONDITIONING HVAC 3Check of Output Equipment F01RY00004...

Page 140: ...CONDITIONING HVAC 1A 111 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 foll...

Page 141: ...pection Go to Step 2 Replace the in car sensor 2 Is there continuity between the harness side connector No I33 1 and No I34 3 Go to Step 4 Go to Step 3 3 Repair an open circuit between terminal No I33...

Page 142: ...ion Go to Step 2 Replace the ambient sensor 2 Connect the ambient sensor connector Is resistance between the harness side connector No I33 2 and No I33 11 normal Refer to the later section on Individu...

Page 143: ...tinuity between the harness side connector terminal No I33 3 and No I35 2 Go to Step 4 Go to Step 4 3 Repair an open circuit between terminal No I33 3 and No I35 2 Is the action complete Go to Step 2...

Page 144: ...HEATING VENTILATION AND AIR CONDITIONING HVAC 1A 115 Inspection of the Intake Actuator System D08RY00142...

Page 145: ...ss side connector terminal No I49 3 and ground Approx 12V Go to Step 6 Go to Step 5 5 Repair an open circuit between terminal No I49 3 and No B36 4 Is the action complete Go to Step 4 6 Is the battery...

Page 146: ...o to Step 9 Go to Step 8 8 Repair an open circuit between terminal No I49 6 and No I33 12 Is the action complete Go to Step 7 9 Is there continuity between the harness side connector terminal No I49 1...

Page 147: ...18 HEATING VENTILATION AND AIR CONDITIONING HVAC Inspection of the Mix Actuator System D08RY00145 Condition Possible cause Correction Does not work at all Refer to Chart A Control failure Refer to Cha...

Page 148: ...sing 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...

Page 149: ...Go to Step 3 5 Is there continuity between harness side connector terminal No I45 7 and No I33 5 Go to Step 7 Go to Step 6 6 Repair an open circuit between terminal No I45 7 and No I33 5 Is the actio...

Page 150: ...NG VENTILATION AND AIR CONDITIONING HVAC 1A 121 Inspection of the Mode Actuator System D08RY00146 Condition Possible cause Correction Does not work at all Refer to Chart A Control failure Refer to Cha...

Page 151: ...F 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 4 Replace the auto air conditioner contr...

Page 152: ...and No I33 10 Go to Step 7 Go to Step 6 6 Repair an open circuit between terminal No B69 3 and No I33 10 Is the action complete Go to Step 5 7 Is there continuity between harness side connector termin...

Page 153: ...1A 124 HEATING VENTILATION AND AIR CONDITIONING HVAC Inspection of the Fan Motor System D08RY00144...

Page 154: ...urn on the ignition switch the engine is run Is the battery voltage applied between the harness side connector terminal No B5 1 and ground Go to Step 5 Go to Step 4 4 Repair an open circuit between te...

Page 155: ...s side connector terminal No I51 4 and ground No B 2 Go to Step 6 Go to Step 5 5 Repair an open circuit between terminal No I51 4 and ground No B 2 Is the action complete Go to Step 4 6 Is the battery...

Page 156: ...3 Repair an open circuit between terminal No B5 2 and I50 1 No B5 2 and I33 17 Go to Step 2 4 Is there continuity between the harness side connector terminal No I50 3 and ground No B 2 Go to Step 6 G...

Page 157: ...B5 2 and I33 17 Is the action complete Verify repair 3 Is the max high relay normal Refer to the later section on individual inspection Go to Step 4 Replace the relay 4 Reinstall the max high relay Do...

Page 158: ...HEATING VENTILATION AND AIR CONDITIONING HVAC 1A 129 Inspection of the Magnetic Clutch System 6VE1 Engine D08RY00143...

Page 159: ...d No E3 1 Is the action complete Go to Step 7 9 Is the battery voltage applied between the harness side connector terminal No X7 2 and ground No X7 1 and ground Go to Step 11 Go to Step 10 10 Repair a...

Page 160: ...0 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 Is the action complete V...

Page 161: ...sensor side terminal No I34 3 and No I34 4 865RY00011 Sun Sensor 1 Disconnect the sun sensor connector I 35 2 Measure the current value on the sun sensor when placed it approximately 15 cm away from 6...

Page 162: ...Check the conduction between the MAX HI relay side terminals C01RY00003 In Car Sensor 1 Turn on the ignition switch the engine is started Start the air conditioner in Full Auto 2 Make sure that the i...

Page 163: ...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 t...

Page 164: ...einforcement 6 Disconnect the power transistor connector 7 Remove power transistor Installation To install follow the removal step in the reverse order Automatic Heater Air Conditioner Control Unit 86...

Page 165: ...ter air conditioner control unit section 3 Remove in car sensor Installation To install follow the removal step in the reverse order Ambient Sensor 875RY00001 Legend 1 Ambient Sensor 2 Sensor Connecto...

Page 166: ...or Installation To install follow the removal step in the reverse order Electronic Thermostat 874RX022 Legend 1 Duct Sensor 2 Evaporator Core 3 Evaporator Assembly 4 Thermostat Assembly Removal 1 Disc...

Page 167: ...To install follow the remove step in the reverse order Mix Actuator 860RY00009 Legend 1 Instrument Panel Assembly 2 Actuator Rod 3 Mix Actuator 4 Instrument Panel Center Bracket Removal 1 Disconnect...

Page 168: ...nector Removal 1 Disconnect the battery ground cable 2 Discharge and recover refrigerant D Refer to Refrigerant Recovery in this section 3 Remove the evaporator assembly D Refer to Evaporator Assembly...

Page 169: ...Parts 2A 34 Removal 2A 35 Inspection and Repair 2A 35 Installation 2A 35 Outer Track Rod Assembly 2A 36 Outer Track Rod Assembly and Associated Parts 2A 36 Removal 2A 37 Inspection and Repair 2A 37 In...

Page 170: ...nerally 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 Fo...

Page 171: ...te The smaller opening contains the pressure line union flow control valve and spring Pressure Switch When hydraulic pressure reaches 3650 350 kPa 530 50 psi the pressure switch of the power steering...

Page 172: ...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 an...

Page 173: ...the problems in steering suspension wheels and tires involve several systems they must all be considered when diagnosing a complaint To identify the symptom always road test the vehicle first Proceed...

Page 174: ...lower ball joint Replace ball joint Improper wheel alignment Check wheel alignment Steering gear misadjustment Check and adjust pinion torque Tire not adequately inflated Inflate tires to proper press...

Page 175: ...hten 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 ste...

Page 176: ...frozen steering shaft bearing Replace steering assembly Steering gear misadjustment Adjust the steering gear Sticky or plugged steering gear valve Repair or replace steering gear valve Entry of air in...

Page 177: ...air steering unit or pump Scored side plate or rotor Replace side plate or rotor Worn cam ring Replace cam ring Groaning Noise In Steering Pump Air in the fluid Bleed hydraulic system Low fluid level...

Page 178: ...ace 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 screws Tighten mounting screws Tu...

Page 179: ...The gauge must be between the shutoff valve and pump Open the shutoff valve 3 Check the fluid level Fill the reservoir with power steering fluid to the Full mark Start the engine then turn the steerin...

Page 180: ...vel 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...

Page 181: ...e 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 sh...

Page 182: ...ould 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 480RS003 Toe in is the measured amount the fro...

Page 183: ...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 4...

Page 184: ...thin 30 450RS004 450RS005 NOTE Overall thickness of caster shim and camber shim should be 10 8 mm 0 425 in or less Tighten the fulcrum pin bolt to the specified torque Torque 152 N m 112 lb ft Positio...

Page 185: ...wheel on the turning radius gauge in a straight ahead position 2 Set the parking brake firmly 3 Adjust the inside wheel angle of each side with the stop bolts NOTE The maximum protruding length 1 of s...

Page 186: ...ED SYSTEM 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 Spec...

Page 187: ...SSISTED SYSTEM 2A 19 Special Tools ILLUSTRATION TOOL NO TOOL NAME J 29877 A Tester Power steering J 39213 Adapter Power steering tester J 29107 Remover Pitman arm J 26508 Installer Extension housing o...

Page 188: ...itman Arm 4 Nut 5 Gear Box Mounting Bolt and Nut 6 Gear Box Removal 1 Remove the stone guard 2 Remove the lower fan shroud Refer to Radiator in Engine section 3 Disconnect stabilizer bar at the stabil...

Page 189: ...RS004 9 Remove gear box Installation 1 Align the setting marks 1 made at removal then install gear box 431RW004 2 Tighten gear box mounting bolt and nut to specified torque Torque 44 N m 33 lb ft 3 Ti...

Page 190: ...eering Gear Disassembled View 440RS001 Legend 1 Dust Cover 2 Retaining Ring 3 Back Up Ring 4 Oil Seal 5 Ball nut and Valve Housing Assembly 6 O ring 7 Seal Ring 8 O ring 9 Gear Box 10 Sector Shaft 11...

Page 191: ...in the outlet side 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 6...

Page 192: ...abnormal conditions D Bearing D Ball nut and valve housing D Sector shaft D Top cover D Gear box D Needle bearing D Dust seal D Seal ring D Gasket Ball nut Rotation 440RS006 Hold the ball nut and val...

Page 193: ...ll o ring 3 Apply a thin coat of power steering fluid to the new seal ring 1 and be sure to discard used part then install seal ring 4 Apply a thin coat of power steering fluid to the new O ring and b...

Page 194: ...0kg 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...

Page 195: ...POWER ASSISTED SYSTEM 2A 27 Main Data and Specifications General Specifications Steering unit Type Integral ball screw Gear ratio 16 3 1 Torque Specifications E03RS003...

Page 196: ...ring Pump and Associated Parts 436RW003 Legend 1 Hose Suction 2 Hose Flexible 3 Bolt 4 Belt 5 Pulley 6 Pump Assembly Removal 1 Drain the engine coolant 2 Place a drain pan below the pump 3 Remove the...

Page 197: ...e specified torque Torque 56 N m 41 lb ft 2 Install the pump assembly Connect the harness under the pump housing 3 Tighten the fixing bolt to the specified torque Torque 46 N m 34 lb ft 4 Connect the...

Page 198: ...25 O ring 26 Connector 27 Pressure Switch Disassembly 1 Clean the oil pump with solvent plug the discharge and suction ports to prevent the entry of solvent Be careful not to expose the oil seal of sh...

Page 199: ...should be replaced as a subassembly Cam The inner face of the arm should have a uniform contact pattern without a sign of step wear When part replacement becomes necessary the pump cartridge should be...

Page 200: ...ring and be sure to discard used parts 10 Install a new gasket and be sure to discard used parts 11 Install rear housing and pump cartridge 12 Install bolt and tighten it to the specified torque Torqu...

Page 201: ...POWER ASSISTED SYSTEM 2A 33 Main Data and Specifications General Specifications Oil pump Type Vane Operating fluid ATF DEXRON III Torque Specifications E02RX005...

Page 202: ...ISTED SYSTEM Center Track Rod Assembly Center Track Rod Assembly and Associated Parts 433RW001 Legend 1 Nut and Cotter Pin 2 Nut and Cotter Pin Pitman Arm 3 Nut and Cotter Pin Relay Lever 4 Center Tra...

Page 203: ...nspection and Repair Make necessary correction or parts replacement if wear damage corrosion bending deteriorations or any other abnormal condition are found through inspection Check the ball joint Bo...

Page 204: ...Assembly Outer Track Rod Assembly and Associated Parts 433RS012 Legend 1 Rod End Assembly Inner 2 Lock Nut Inner Left hand threads 3 Lock Nut Outer 4 Rod End Assembly Outer 5 Nut and Cotter Pin Knuckl...

Page 205: ...3 4 Remove outer lock nut 5 Apply setting marks 1 to ensure reassembly of the parts in their original position then remove outer rod end assembly 433RS014 6 Remove inner lock nut NOTE For either outer...

Page 206: ...torque Torque 118 N m 87 lb ft 5 Install knuckle arm nut and cotter pin then tighten the nut to the specified torque with just enough additional torque to align cotter pin holes Install new cotter pin...

Page 207: ...Bolt and Nut 2 Relay Lever and Bracket 3 Bracket 4 Relay Lever 5 Nut and Washer 6 Nut and Cotter Pin Removal 1 Raise the vehicle and support the frame with suitable safety stands 2 Remove nut and cott...

Page 208: ...rom the bracket 433RS019 7 Remove bracket Installation 1 Install bracket 2 Install relay lever 3 Install nut and washer and tighten the nut to the specified torque Torque 118 N m 87 lb ft 4 Install re...

Page 209: ...POWER ASSISTED SYSTEM 2A 41 Steering Linkage and Associated Parts Main Data and Specifications Torque Specifications E03RS004...

Page 210: ...2A 42 POWER ASSISTED SYSTEM Special Tools ILLUSTRATION TOOL NO TOOL NAME J 36831 Tie rod end remover J 22912 01 Relay lever remover...

Page 211: ...COVER ARE POINTED AWAY FROM YOU NEVER CARRY AN AIR BAG ASSEMBLY BY THE WIRES OR CONNECTOR ON THE UNDERSIDE OF MODULE IN THE CASE OF AN ACCIDENTAL DEPLOYMENT THE BAG WILL THEN DEPLOY WITH MINIMAL CHAN...

Page 212: ...and pull it The cover insulator slides and lock will be released Do not hold the socket insulator 2 827RW028 Installation To install the connector hold the soket insulator 1 and insert it The cover in...

Page 213: ...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...

Page 214: ...e 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 modu...

Page 215: ...olumn assembly could cause the jacket to bend or deform Any of the above damage could impair the column s collapsible design If it is necessary to remove the steering wheel use only the specified stee...

Page 216: ...IS PROVIDED TO ALLOW THE AIR CUSHION TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT OTHERWISE PERSONAL INJURY MAY RESULT 827RS016 7 Disconnect horn lead 8 Remove steering wheel fixing nut 9...

Page 217: ...r 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 ass...

Page 218: ...ery terminal cable and wait at least 5 minutes 4 Disconnect the yellow 2 way SRS connector located under the steering column CAUTION The wheels of the vehicle must be straight ahead and the steering c...

Page 219: ...E 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 82...

Page 220: ...n Then turn the SRS coil counterclockwise to full return about 3 turns and align the neutral mark CAUTION When turning the SRS coil counterclockwise to full stop turning if resistance is felt Forced f...

Page 221: ...odel has white bar codes label NOTE Pass the lead wire through the tabs on the plastic cover wire protector of inflator to prevent lead wire from being pinched 6 Secure the module with one bolt to rel...

Page 222: ...on switch to LOCK 3 Disconnect the battery terminal cable and wait at least 5 minutes 4 Disconnect the yellow 2 way SRS connector located under the steering column CAUTION The wheels of the vehicle mu...

Page 223: ...odule 827RW002 10 Apply a setting mark 1 across the steering wheel and shaft so parts can be reassembled in their original position 430RW001 11 Move the front wheels to the straight ahead position the...

Page 224: ...move the SRS coil from the combination switch assembly 825RW030 15 Remove snap ring 16 Remove cushion rubber 17 Remove shift lock cable for A T 18 Disconnect the starter switch harness connector locat...

Page 225: ...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 19...

Page 226: ...sembly 8 Shift Lock Cable For A T 9 Steering Column Assembly 10 Front Console Assembly 11 Lower Cluster Assembly 12 Steering Lower Cover 13 Driver Knee Bolster reinforcement Removal 1 Turn the steerin...

Page 227: ...from behind the steering wheel assembly using a TORX driver or equivalent until the inflator module can be released from steering assembly 827RT008 12 Disconnect the yellow 2 way SRS connector located...

Page 228: ...arter switch harness connector located under the steering column then remove lock cylinder assembly 22 Apply a setting mark 1 across the universal joint and steering shaft to reassemble the parts in t...

Page 229: ...injected plastic pins for any loose conditions or damage 431RW033 Shaft Length Check the shaft length from the upper end of the slide joint to the end of the shaft If column length is not in specific...

Page 230: ...ng harness connector and the SRS 2 way connector located under the steering column 11 Turn the SRS coil counterclockwise to full return about 3 turns and align the neutral mark CAUTION When turning th...

Page 231: ...rom being pinched 16 Secure the module with one bolt to relieve weight on the wire connector 17 Tighten bolts to specified sequence as illustrated Torque 8 N m 69 lb in 827RW003 18 Install driver knee...

Page 232: ...2A 64 POWER ASSISTED SYSTEM Supplemental Restraint System Steering Wheel Column and Associated Parts Main Data and Specifications Torque Specifications E03RW001...

Page 233: ...POWER ASSISTED SYSTEM 2A 65 Special Tools ILLUSTRATION TOOL NO TOOL NAME J 29752 Steering wheel remover...

Page 234: ...oval 3C 24 Inspection and Repair 3C 25 Installation 3C 25 Main Data and Specifications 3C 26 Special Tools 3C 27 Service Precaution WARNING THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM SRS REFER T...

Page 235: ...of control arms stabilizer bar shock absorber and a torsion bar The front end of the torsion bar is attached to the lower control arm The rear of the torsion bar is mounted into a height control arm...

Page 236: ...ber 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 whe...

Page 237: ...ts 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...

Page 238: ...iper Warped discs Replace brake disc Badly worn brake pads Replace brake pads Tires are inflated unequally Inflate tires to proper pressure Low or Uneven Trim Height Broken or sagging springs Replace...

Page 239: ...move rubber bushing and washer 6 Remove shock absorber 7 Remove rubber bushing and washer Inspection and Repair Make necessary correction or parts replacement if wear damage corrosion or any other abn...

Page 240: ...eak the ball joint boot 5 Remove link 6 Remove bracket 7 Remove stabilizer bar 8 Remove rubber bushing Inspection and Repair Make necessary correction or parts replacement if wear damage corrosion or...

Page 241: ...S003 Legend 1 Adjust Bolt End Piece and Seat 2 Height Control Arm 3 Torsion Bar Removal 1 Raise the vehicle and support the frame with suitable safety stands 2 Apply the setting marks 1 to the adjust...

Page 242: ...06 Inspection and Repair Make necessary correction or parts replacement if wear damage corrosion or any other abnormal conditions are found through inspection Check the following parts D Torsion bar D...

Page 243: ...he bolt portion of the end piece 4 Apply grease to the portion of the seat 5 that fits into the bracket 410RS008 4 Apply grease to the serrated portions 5 Install adjust bolt and seat then turn the ad...

Page 244: ...stands 2 Remove wheel and tire assembly Refer to Wheel Replacement in this section 3 Remove the brake caliper Refer to Disc Brakes in Brake section 4 Remove the hub assembly Refer to Front Hub and Dis...

Page 245: ...assembly 13 Remove oil seal 14 Remove washer 15 Remove needle bearing by using remover J 23907 901RW044 Inspection and Repair Make necessary correction or parts replacement if wear damage corrosion o...

Page 246: ...thrust washer 901RW046 4 Install knuckle assembly 5 Install upper ball joint and tighten the nut to the specified torque with just enough additional torque to align cotter pin holes Install new cotter...

Page 247: ...Speed Sensor Cable 11 Nut and Cotter Pin 12 Upper Ball Joint Removal 1 Raise the vehicle and support the frame with suitable safety stands 2 Remove wheel and tire assembly Refer to Wheel Replacement...

Page 248: ...Remove caster shims and note the positions and number of shims 12 Remove upper control arm assembly 13 Remove nut 14 Remove plate 15 Remove bushing by using remover J 29755 901RW047 901RW048 16 Remove...

Page 249: ...t and tighten fulcrum pin nut finger tight NOTE Torque fulcrum pin nut after adjusting buffer clearance Buffer clearance 20 mm 0 79 in Torque 108 N m 80 lb ft 450RS012 5 Install upper control arm asse...

Page 250: ...n the bolt to the specified torque Torque 152 N m 112 lb ft 10 Install upper ball joint and tighten it to the specified torque Torque 57 N m 42 lb ft 11 Install nut and cotter pin then tighten the nut...

Page 251: ...Ball Joint 13 Shock Absorber 14 Stabilizer Link Removal 1 Raise the vehicle and support the frame with suitable safety stands 2 Remove wheel and tire assembly Refer to Wheel Replacement in this sectio...

Page 252: ...ower 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 co...

Page 253: ...036 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 torqu...

Page 254: ...clearance 20 mm 0 79 in Torque 196 N m 145 lb ft 450RS012 14 Install front nut and washer then tighten lower link nut finger tight NOTE Torque lower control arm nut after adjusting buffer clearance B...

Page 255: ...t Upper Ball Joint and Associated Parts 450RS022 Legend 1 Bolt Nut and Washer 2 Upper Ball Joint 3 Nut and Cotter Pin Removal 1 Raise the vehicle and support the frame with suitable safety stands 2 Re...

Page 256: ...confirm its normal movement D Inspect screw taper area of ball for damage D If any defects are found by the above inspections replace the ball joint assembly with new one 450RS023 D After moving the...

Page 257: ...ement in this section 3 Remove the outer track rod from the knuckle Refer to Steering Linkage in Steering section 4 Remove the retaining ring from the front axle driving shaft to release the shaft fro...

Page 258: ...y defects are found by the above inspections replace the ball joint assembly with new one 450RS026 D After moving the ball joint 4 or 5 times attach nut the measure the preload Starting torque 0 5 6 4...

Page 259: ...ith 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...

Page 260: ...ring J 8092 Grip J 41468 Installer Oil seal J 39376 Installer Upper arm bushing J 29755 Remover and Installer Upper arm bushing ILLUSTRATION TOOL NO TOOL NAME J 36833 Remover and Installer kit Lower a...

Page 261: ...EM SRS REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING WHEN YOU ARE PERFORMING SERVICE ON O...

Page 262: ...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...

Page 263: ...safety stands 2 Support the rear axle case with a jack 3 Remove the parking brake cable bracket from the trailing link 4 Disconnect the stabilizer bar at the stabilizer link 5 Remove the shock absorb...

Page 264: ...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 spr...

Page 265: ...Check the following parts D Shock absorber D Rubber bushing Axle side NOTE When mounting rubber bushings be sure not to use grease on bushings or any other nearby part Installation 1 Install shock abs...

Page 266: ...rking brake cable from the trailing link 2 Remove the trailing link fixing bolt and nut 3 Remove trailing link Inspection and Repair Make necessary correction or parts replacement if wear damage corro...

Page 267: ...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 bolt...

Page 268: ...eed 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 Inspection and Repair Make necessary correction or parts replace...

Page 269: ...stall center link Make sure that the center link is in its correct position NOTE When mounting center link be sure not to use grease bushings or any other nearby part 460RS010 2 Install bolt and nut T...

Page 270: ...1 Remove nut and washer 2 Remove bolt and nut 3 Remove lateral rod Inspection and Repair Make necessary correction or parts replacement if wear damage corrosion or any other abnormal condition are fou...

Page 271: ...01RW063 Installation 1 Install lateral rod and make sure that the lateral rod is in its correct position NOTE When mounting lateral rod be sure not to use grease on bushings or any other nearby part 4...

Page 272: ...and tire assembly Refer to Wheel Replacement in this section 3 Remove nut and washer 4 Remove link CAUTION Be careful not to damage the ball joint boot 5 Remove bracket 6 Remove rubber bushing 7 Remov...

Page 273: ...stall stabilizer bar 2 Install rubber bushing 3 Install bracket and tighten to the specified torque Torque 22 N m 16 lb ft 4 Install link 5 Install nut and washer then tighten the nut to the specified...

Page 274: ...ing 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 Pis...

Page 275: ...3D 15 REAR SUSPENSION Torque Specifications E03RW006...

Page 276: ...ION Special Tools ILLUSTRATION TOOL NO TOOL NAME J 39214 Remover and Installer Trailing center link bushing J 39792 Remover and Installer Lateral rod bushing axle side J 39215 Remover and Installer La...

Page 277: ...ERVICE INFORMATION FAILURE TO FOLLOW WARNING COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT PERSONAL INJURY OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS CAUTION Always use the correct fastener in the proper...

Page 278: ...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 belte...

Page 279: ...life 480RS002 Legend 1 Spare Tire If the following conditions are noted rotate the tires D Front tire wear is different from rear D Uneven wear exists across the tread of any tire D Left and right fr...

Page 280: ...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 Wad...

Page 281: ...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 wh...

Page 282: ...ont side Was a problem corrected Replace tire Install a known good tire in place of other front tire If lead corrected replace tire Typical examples of abnormal tire ahead wear and major causes CAUTIO...

Page 283: ...d Shoulder wear generally wear develops in outer shoulder 480RW005 1 Camber or toe in incorrect 2 Shoulder wear caused by repeated hard cornering Wear in shoulders at points opposed to each other 480R...

Page 284: ...3E 8 WHEEL AND TIRE SYSTEM One sided feather edging 480RW008 1 Wear caused by repeated hard cornering 2 Camber or toe in incorrect...

Page 285: ...arings Installation 1 Install wheel and tire 2 Install wheel lug nut and lower the vehicle Tighten the wheel lug nuts to the specified torque in numerical order Torque 118 N m 87 lb ft CAUTION Before...

Page 286: ...R TIRE WHEN INFLATING BEAD MAY BREAK WHEN BEAD SNAPS OVER RIM S SAFETY HUMP AND CAUSE SERIOUS PERSONAL INJURY NEVER EXCEED 240 KPA 35 PSI PRESSURE WHEN INFLATING IF 240 KPA 35 PSI PRESSURE WILL NOT SE...

Page 287: ...WARNING STONES SHOULD BE REMOVED FROM THE TREAD TO AVOID OPERATOR INJURY DURING SPIN BALANCING AND TO OBTAIN A GOOD BALANCE Balancing Wheel and Tire On vehicle Balancing On Vehicle balancing methods...

Page 288: ...nd Specifications General Specifications 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 kP...

Page 289: ...RMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING WHEN YOU ARE REFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING REFER TO THE SRS SERVICE INFORMA...

Page 290: ...ign 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 incorrect Adjust the backlash Worn or chipped...

Page 291: ...ssociated Parts 415RW015 Legend 1 Flange Nut 2 Flange 3 Oil Seal 4 Outer Bearing 5 Collapsible Spacer Removal 1 Raise the vehicle and support it at the frame The hoist must remain under the front axle...

Page 292: ...on Check the following parts 1 Seal surface of the pinion 2 Cage bore for burns Installation 1 Install collapsible spacer Discard the used collapsible spacer and install a new one 2 Install outer bear...

Page 293: ...Spacer 3 Breather Hose 4 Shift Switch Connector 5 Protector 6 Front Axle Case Assembly and Front Drive Shaft Assembly LH side 7 Hub Assembly Disc Back Plate and Knuckle 8 Front Drive Shaft Assembly RH...

Page 294: ...nt Hub and Disc in this section 5 Disconnect the knuckle and the suspension arm Refer to Suspension section 6 Remove steering link and arm assembly refer to Steering Linkage in Steering section 7 Remo...

Page 295: ...haft assembly LH 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 fron...

Page 296: ...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 tight...

Page 297: ...ter Bearing Outer Race 8 Damper 9 Bracket 10 Differential Carrier 11 Bearing Cap 12 Bolt 13 Inner Bearing Outer Race 14 Collapsible Spacer 15 Pinion Gear 16 Inner Bearing 17 Adjust Shim 18 Diff Cage A...

Page 298: ...Remove differential cage assembly 7 Remove side bearing outer race after removal keep the right and left hand side bearing assemblies separate to maintain inner and outer race combinations 8 Remove si...

Page 299: ...apsible spacer 15 Remove the inner bearing using a separator J 22912 01 and a press 415RS006 16 Remove adjust shim 17 Remove inner bearing outer race 18 Remove oil seal 19 Remove outer bearing 20 Remo...

Page 300: ...ner bearing outer race 415RS008 3 Install adjust shim and adjust drive pinion mounting distance 1 Apply gear oil to the inner and outer drive pinion bearing Clean the pinion setting gauge set Then ins...

Page 301: ...e needle has made a half turn clockwise Tighten down the dial indicator in this position 425RS020 Legend 1 Dial Indicator 2 Ganging Arbor 3 Plunger 4 Gauge Plate 5 Position the plunger on the gauge pl...

Page 302: ...ion 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...

Page 303: ...6 0 0929 2 38 0 0937 2 42 0 0953 2 44 0 0961 2 46 0 0969 2 48 0 0977 0 094 2 26 0 0890 2 28 0 0898 2 32 0 0914 2 34 0 0921 2 36 0 0929 2 38 0 0937 2 42 0 0953 2 44 0 0961 2 46 0 0969 2 48 0 0977 2 52...

Page 304: ...flange 11 Install flange nut 1 Apply lubricant to the pinion threads 2 Tighten the nut to the specified torque using the pinion flange holder J 37221 Torque 177 275N m 130 203 lb ft NOTE Discard used...

Page 305: ...mage 425RS029 Legend 1 Drive handle J 8092 2 Installer J 24244 3 Pilot J 8107 2 2 Insert the differential cage assembly with bearing outer races into the side bearing bores of the carrier 425RS030 3 U...

Page 306: ...shims required and add 0 05 mm 0 002 in to each shim pack to provide side bearing preload Always use new shims 5 Use bearing remover J 22888 and pilot J 8107 2 to remove side bearing 415RS013 13 Insta...

Page 307: ...1 in Limit 0 05 mm 0 002 in 425RS037 Gear Tooth Contact Pattern Check and Adjustment 1 Apply a thin coat of prussian blue or equivalent to the faces of the 7 8 teeth of the ring gear Check the impress...

Page 308: ...erential case and the carrier assembly to the front axle case and tighten the nuts and bolts Torque 25 N m 19 lb ft 415RS014 3 Fill the axle case with hypoid gear lubricant to just below the filler ho...

Page 309: ...d View 415RS015 Legend 1 Pinion Gear 2 Thrust Washer 3 Side Gear 4 Cross Pin 5 Ring Gear 6 Bolt 7 Differential Cage 8 Lock Pin Disassembly 1 Remove bolt 2 Remove ring gear 3 Remove lock pin break stak...

Page 310: ...tial 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 a...

Page 311: ...3 0 014 in Limit 0 5m 0 02 in 425RS047 Reassembly 1 Install thrust washer 2 Install side gear 3 Install the pinion gear by engaging it with the side gears while turning both pinion gears simultaneousl...

Page 312: ...cure the lock pin 425RS051 Legend 1 Staked Portion 2 Lock Pin 6 Clean the ring gear threaded holes to remove the locking agent When installing the ring gear apply LOCTITE 271 or equivalent to all the...

Page 313: ...e 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 Ref...

Page 314: ...DIFFERENTIAL FRONT 4A1 26 E04RW003...

Page 315: ...rential holding fixture Use with J 3289 20 base J 3289 20 Holding fixture base J 22888 Puller Side bearing J 8107 2 Adapter Side bearing plug ILLUSTRATION TOOL NO TOOL NAME J 22912 01 Separator J 2425...

Page 316: ...NO TOOL NAME J 23597 7 Gauge plate J 8001 Dial indicator J 23597 8 Disc J 23597 1 Arbor J 6133 01 Installer Pinion bearing J 39209 Punch End nut lock ILLUSTRATION TOOL NO TOOL NAME J 24244 Installer...

Page 317: ...THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING WHEN YOU ARE REFORMING SERVICE ON OR NEAR THE SRS CO...

Page 318: ...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...

Page 319: ...on The pinion bearing preload is set by crushing a collapsible spacer between the bearings in the axle housing 420RY00003 The ring gear is bolted onto the differential cage with 12 bolts The different...

Page 320: ...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 r...

Page 321: ...Breather Hose 17 Flare Nut Removal 1 Raise the vehicle and support it with suitable safety stands The hoist must remain under the rear axle housing 2 Remove brake fluid Refer to Hydraulic Brakes in B...

Page 322: ...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...

Page 323: ...aft and Associated Parts 420RY00005 Legend 1 Brake Caliper 2 Brake Disc 3 Wheel Pin 4 Axle Shaft Assembly 5 Back Plate 6 Parking Brake Assembly 7 Bearing Holder 8 Bearing 9 Retainer 10 Snap Ring 11 Bo...

Page 324: ...13 Remove bearing holder 14 Remove back plate 15 Remove the wheel pins using a remover J 6627 A 420RS007 Inspection and Repair Make necessary correction or parts replacement if wear corrosion or any o...

Page 325: ...eal Replacement Remove the oil seal carefully not to damage the bearing holder bore When installing use oil seal installer J 39379 420RS011 Installation 1 Install wheel pin 2 Install back plate 3 Inst...

Page 326: ...e 10 Install parking brake assembly refer to Parking Brakes in Brake section 11 Install antilock brake system sensor 12 Install brake disc 13 Install brake caliper refer to Disk Brakes in Brake sectio...

Page 327: ...on Check the following parts 1 Seal surface of the pinion 2 Cage bore for burns Installation 1 Install collapsible spacer discard the used collapsible spacer and install a new one 2 Install outer bear...

Page 328: ...n the differential oil 4 Remove the propeller shaft Refer to Rear Propeller Shaft in this section 5 Remove the ABS speed sensor Refer to 4 Wheel Anti lock Brake System ABS in Brake section 6 Remove th...

Page 329: ...nd nuts to the specified torque Torque Nuts 44N m 33lb ft Bolts 66N m 48lb ft 3 Install axle shaft assembly Be sure not to damage the oil seal by axle shaft 4 Install nut refer to Axle Shaft in this s...

Page 330: ...eal Slinger 5 Outer Bearing 6 Outer Bearing Outer Race 7 Diff Carrier 8 Bearing Cap 9 Bolt 10 Inner Bearing Outer Race 11 Collapsible Spacer 12 Inner Bearing 13 Adjust Shim Pinion Position 14 Drive Pi...

Page 331: ...r race After removal keep the right and left hand side bearing assemblies separate to maintain inner and outer race combinations 5 Remove side bearing by using remover J 42379 and adapter J 8107 3 Sel...

Page 332: ...e the inner bearing by using remover J 42379 Select insert 303174 and collet halves 44803 in remover kit J 42379 for inner bearing removal 415RW004 12 Remove adjust shim 13 Remove oil seal 14 Remove o...

Page 333: ...en install the gauge set together with the inner and outer bearings Install gauge plate J 42826 3 inner pilot J 42827 2 stud and nut J 21777 43 4 and outer pilot J 42824 1 through inner and outer bear...

Page 334: ...the dial indicator to 0 Repeat the procedure to verify the 0 setting 425RS021 6 After the ZERO setting is obtained rotate the gauging arbor until the dial indicator rod does not touch the gauging pla...

Page 335: ...4 2 32 0 0914 2 34 0 0921 2 34 0 0921 2 36 0 0929 2 36 0 0929 2 38 0 0937 2 38 0 0937 2 40 0 0945 2 40 0 0945 2 42 0 0953 2 42 0 0953 2 44 0 0961 0 093 2 26 0 0890 2 28 0 0898 2 28 0 0898 2 30 0 0905...

Page 336: ...e on seal lip 425RS025 9 Install flange assembly 10 Install flange nut and washer 1 Apply lubricant to the pinion threads 2 Using the pinion flange holder J 8614 01 tighten the nut only enough to remo...

Page 337: ...ms by using installer J 42829 and grip J 8092 425RW003 2 Insert the differential cage assembly with bearing outer races into the side bearing bores of the carrier 425RS030 3 Using two sets of feeler g...

Page 338: ...of the shims required and add 0 05 mm 0 002 in to each shim pack to provide side bearing preload Always use new shims 5 Remove side bearing by using remover J 42379 and adapter J 8107 3 415RW003 12 In...

Page 339: ...and Adjustment 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...

Page 340: ...FERENTIAL REAR Differential Cage Assembly Disassembled View 415RY00001 Legend 1 Pinion Mate Gear 2 Thrust Washer for Side Gear 3 Side Gear 4 Differential Shaft 5 Ring Gear 6 Bolt 7 Differention Cage 8...

Page 341: ...parts D Ring gear pinion gear D Bearing D Side gear pinion mate gear differential shaft D Differential cage carrier D Thrust washer D Oil seal Ring gear replacement 1 The ring gear should always be r...

Page 342: ...Reassembly Differential cage Thrust washer Side gear Pinion gear 1 Install the pinion gear by engaging it with the side gears while turning both pinion gears simultaneously in the same direction 2 Ins...

Page 343: ...047 0 051 425RY00008 4 Install lock pin D Install the lock pin using small drift 425RY00009 5 Install exciter ring If equipped with rear wheel antilock D Press the exciter ring on the differential cag...

Page 344: ...riction plate 7 Friction Plate 8 Friction disc 9 Friction Plate 10 Friction disc 11 Friction Plate 12 Pressure ring 13 Side gear 14 Pinion and Pinion shaft 15 Side gear 16 Pressure ring 17 Friction Pl...

Page 345: ...iction plate 10 Remove Friction disc 11 Remove Friction plate 12 Remove Friction disc 13 Remove Friction plate 14 Remove Pressure ring 15 Remove Side gear 16 Remove Pinion and pinion shaft 17 Remove S...

Page 346: ...r surface of the differential case Repair burrs and nicks using an oil stone D Thrust washer 425RS058 Legend 9 Sliding surface with the side gear or case 10 Peripheral groove of the side gear Repair l...

Page 347: ...Limit A B 0 1 mm 0 004 in Remarks A Inner or outer projections B Sliding surface subjected to abrasion 425RS062 Measure the wear of the thrust washer Limit 1 3 mm 0 05 in 425RS063 Reassembly Adjust th...

Page 348: ...2 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...

Page 349: ...mounting direction is correct as shown in figure 425RY004 Legend 1 Friction Plate 2 Spring Disc 3 Friction Disc 4 Install Friction disc 5 Install Friction plate 6 Install Friction plate 7 Install Fric...

Page 350: ...4A2 34 DIFFERENTIAL REAR 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...

Page 351: ...1 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 Lim...

Page 352: ...over Axle shaft bearing J 39212 Installer Axle shaft bearing J 39379 Installer Outer axle seal J 8614 01 Pinion flange holder ILLUSTRATION TOOL NO TOOL NAME J 37263 Installer Pinion oil seal J 42832 H...

Page 353: ...Inner bearing outer race J 42824 Pilot Outer J 21777 43 Nut Stud J 44453 Pilot Inner J 44449 Pilot Outer bearing ILLUSTRATION TOOL NO TOOL NAME J 44451 Gage plate J 8001 Dial indicator J 44452 Disc 2...

Page 354: ...LLUSTRATION TOOL NO 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 scre...

Page 355: ...ERFORMING 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 OTHERWI...

Page 356: ...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 prope...

Page 357: ...complete the connecting transfer front output gear to or disconnecting it from front propeller shaft condition of the transfer position switch changes The vacuum solenoid valve VSV is driven by the s...

Page 358: ...t completed the motor reverses its rotation for 1 2 seconds and tries again to shift transfer gear This procedure is repeated 3 times in maximum While this procedure 4WD indicator lamp blinks by 2 Hz...

Page 359: ...dition continues for 2 seconds the shifting to 2WD is stopped and the indicator lamp s blinking changes from 2Hz to 4Hz to notify driver of wrong operation Time Chart of Shifting from 4WD to 2WD at 4L...

Page 360: ...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 Clos...

Page 361: ...eels 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 possibl...

Page 362: ...RIVE LINE CONTROL SYSTEM SHIFT ON THE FLY Parts Location D08RX005 Legend 1 I 12 2 I 9 3 H 7 H 24 H 25 4 Fuse Box 5 C 16 6 C 94 7 M 11 M 12 8 M 22 9 M 23 10 M 24 11 H 10 12 M 26 13 Relay Fuse Box 14 H...

Page 363: ...4B1 9 DRIVE LINE CONTROL SYSTEM SHIFT ON THE FLY Wiring Diagram D08RW028...

Page 364: ...4B1 10 DRIVE LINE CONTROL SYSTEM SHIFT ON THE FLY D08RW029...

Page 365: ...4B1 11 DRIVE LINE CONTROL SYSTEM SHIFT ON THE FLY Connector List D04RW030...

Page 366: ...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...

Page 367: ...semble the transfer case for check Trace this chart from the start after repair or replace 3 Pull out the hoses from vacuum actuator and operate 4WD switch Is there negative pressure on either of hose...

Page 368: ...es No 1 Does the indicator turn out by ignition off Go to Step 2 Short circuit of the indicator harness 2 Is the 4WD switch on 2WD position Disconnection on the 4WD switch harness or breakdown of the...

Page 369: ...r 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 switch Is there negative pressure on either of hoses Go to Step 4 Fau...

Page 370: ...igh to 4L or vice versa 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 replac...

Page 371: ...switch 2 Check the circuit to indicator Was a problem found Trace this chart from the start after repair or replace Disassemble axle ASM for check Trace this chart from the start after repair or repl...

Page 372: ...Check the circuit to indicator Was a problem found Trace this chart from the start after repair or replace Disassemble axle ASM for check Trace this chart from the start after repair or replace 4 1 C...

Page 373: ...4B1 19 DRIVE LINE CONTROL SYSTEM SHIFT ON THE FLY Shift On The Fly Vacuum Piping And Electric Equipment Vacuum piping diagram C04RW007 VSV Assembly Actuator Assembly 412RS032 Vacuum Tank 412RS033...

Page 374: ...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 Hos...

Page 375: ...re is no continuity check transfer shift switch and wiring Inspect both VSVs as follows F04RS004 1 With battery not connected Usual A C There is continuity B Closed 2 With battery connected A B There...

Page 376: ...412RX001 Legend 1 2WD 2 4WD 3 Shift Rod 4 Connector 3 Connect the terminals as shown in figure Shift rod of the motor actuator moves and stops at 2WD position 412RX002 Legend 1 2WD 2 4WD 3 Shift Rod 4...

Page 377: ...DRIVE LINE CONTROL SYSTEM SHIFT ON THE FLY 4WD Control Unit 4WD Control Unit Associated Parts 412RW044 Legend 1 Lower Cluster Assembly 2 Front Console Assembly 3 Harness Connector 4 Nut 5 4WD Control...

Page 378: ...le 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 ha...

Page 379: ...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 A...

Page 380: ...ving force is directly transmitted to the rear wheels This force is split by the transfer and delivered to the front wheels The magnitude of the torque transmitted to the front wheels is controlled by...

Page 381: ...e 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...

Page 382: ...System Components Parts Location A07RY00002 Legend 1 T F Connector 2 4H Switch and 4L Switch 3 High Low Planetary Gear Set 4 Mechanical Lock 5 Multi Plate Disk Clutch Pack 6 Electromagnetic Coil 7 Rea...

Page 383: ...ller shaft 261RW045 Electromagnetic Coil Receives the duty signals from the TOD control unit and controls the pressing force of the clutch pressure cam 261RW044 Multi Plate Disk Clutch Pack Transmits...

Page 384: ...480 and the corresponding driving force is generated 262RW030 4H and 4L Switch Detects the shift position of the transfer from the movement of the transfer lever and outputs signals to the TOD contro...

Page 385: ...INE CONTROL SYSTEM TOD 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 brac...

Page 386: ...ing 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 si...

Page 387: ...5 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...

Page 388: ...ed 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...

Page 389: ...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...

Page 390: ...iagnostic connector to GND to display the trouble code on the CHECK lamp 821RW021 D If no trouble codes exist code 12 is displayed continuously D If trouble codes exist code 12 is displayed three time...

Page 391: ...amage 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...

Page 392: ...ndition 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 exten...

Page 393: ...4B2 15 DRIVE LINE CONTROL SYSTEM TOD Basic Diagnostic Flow Chart C07RW023 1...

Page 394: ...B2 16 Parts Location D08RW367 Legend 1 I 9 2 C 63 3 H 7 H 8 H 25 4 H 33 5 Fuse Box 6 C 16 7 B 13 8 H 55 H 57 9 M 22 10 M 23 11 M 24 12 H 10 13 H 17 14 E 54 15 E 29 16 Relay Fuse Box 17 H 12 18 B 48 B...

Page 395: ...4B2 17 DRIVE LINE CONTROL SYSTEM TOD Circuit Diagram D04RY00003...

Page 396: ...DRIVE LINE CONTROL SYSTEM TOD 4B2 18 D04RY00002...

Page 397: ...4B2 19 DRIVE LINE CONTROL SYSTEM TOD D04RY00010...

Page 398: ...DRIVE LINE CONTROL SYSTEM TOD 4B2 20 Connector List No Connector face B 13 B 48 B 49 C 16 C 63 C 94 E 29 E 54 H 7 No Connector face H 8 H 10 H 12 H 17 H 25 H 33 H 36 H 55 H 57...

Page 399: ...4B2 21 DRIVE LINE CONTROL SYSTEM TOD No Connector face I 9 I 12 M 22 M 23 M 24 M 27...

Page 400: ...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 T...

Page 401: ...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 Inp...

Page 402: ...ONTENTS 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 plu...

Page 403: ...4 5 V 18 IND c ON STOP DCV 18 46 8 0 14 5 V 20 CHECK LAMP ON STOP DCV 20 46 8 0 14 5 V 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...

Page 404: ...STEM TOD 4B2 26 Tech 2 Scan Tool From 98 MY Isuzu dealer service departments are recommended to use Tech 2 Please refer to Tech 2 scan tool user guide 901RW257 Legend 1 PCMCIA Card 2 SAE 16 19 Adaptor...

Page 405: ...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 ignitio...

Page 406: ...DRIVE LINE CONTROL SYSTEM TOD 4B2 28 060RX062...

Page 407: ...iring abnormality in input 7 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 abno...

Page 408: ...Turn on the starter switch Is the trouble reproduced Replace the ECU and conduct the test run Go to Step 3 Go to Step 2 2 1 Clear the trouble codes 2 Conduct the test run Is the trouble reproduced dur...

Page 409: ...low Trouble code Phenomenon Standard 2 14 Front speed sensor signal open or GND short speed sensor com open 0 3 sensor voltage NOTE The following procedure shows the case that the front or rear sensor...

Page 410: ...ble check flow Go to Step 2 4 Is the continuity between harness of terminal 32 and 45 vehicle side terminal of the front and rear speed sensor Go to Step 5 Repair the circuit Go to Step 6 5 Is the con...

Page 411: ...low Trouble code Phenomenon Standard 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 t...

Page 412: ...terminal 32 and ground vehicle side terminal of the front speed sensor Replace speed sensor Go to Step 3 Repair the circuit Go to Step 3 3 1 Clear the trouble code While running at 30 mph in TOD mode...

Page 413: ...low Trouble code Phenomenon Standard 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 t...

Page 414: ...terminal 45 and ground vehicle side terminal of the rear speed sensor Replace speed sensor Go to Step 3 Repair the circuit Go to Step 3 3 1 Clear the trouble code While running at 30 mph in TOD mode f...

Page 415: ...low Trouble code Phenomenon Standard 5 24 Rear speed sensor signal open or GND short speed sensor COM open 0 3 V sensor voltage NOTE The following procedure shows the case that the front or rear senso...

Page 416: ...ble cheek flow Go to Step 2 4 Is the continuity between harness of terminal 32 and 45 vehicle side terminal of the front and rear speed sensor Go to Step 5 Repair the circuit Go to Step 6 5 Is the con...

Page 417: ...6 13 The reference is short circuited to GND Reference 5 V 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 s...

Page 418: ...harness connector terminals M 27 2 and M 27 7 Replace the front speed sensor Go to Step 8 The reference harness for the front speed sensor is short circuited to GND Repair the circuit Go to Step 8 6 1...

Page 419: ...NTROL SYSTEM TOD Check flow Trouble code Phenomenon Standard 7 21 The voltage of the throttle position sensor TPS is faulty See below table NOTE The signal voltage from the TPS deviates from the stand...

Page 420: ...DRIVE LINE CONTROL SYSTEM TOD 4B2 42 D04RY00012...

Page 421: ...p 3 3 1 Turn off the starter switch 2 Disconnect the ECU connector 3 Turn on the starter switch Does the voltage between terminals B 49 15 and B 48 24 fall within the standard range above The ECU has...

Page 422: ...DRIVE LINE CONTROL SYSTEM TOD 4B2 44 Check flow Trouble code Phenomenon Standard 9 31 The electromagnetic coil is broken D04RY00008...

Page 423: ...ep 5 3 Is the battery voltage always observed between terminals 11 and 22 The harness is short circuited on the battery Repair the circuit Go to Step 5 The phenomenon is not reproduced Refer to Troubl...

Page 424: ...DRIVE LINE CONTROL SYSTEM TOD 4B2 46 Check flow Trouble code Phenomenon Standard 10 26 The electromagnetic coil GND is short circuited Resistance 1 0 to 5 0 ohm at ordi nary temperature D04RY00008...

Page 425: ...en positions does the voltage between terminals 11 and 22 indicate at least 0 1 to 1 0 V The phenomenon is not reproduced Refer to Troubles intermittently observed Go to Step 4 The ECU has failed Repl...

Page 426: ...enon Standard 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...

Page 427: ...V The phenomenon is not reproduced Refer to Troubles intermittently observed Go to Step 7 The shift on the fly system is failed refer to Section 4C Front Axle Go to Step 7 5 Does the TOD indicator sho...

Page 428: ...non Standard 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 syste...

Page 429: ...0V Go to Step 3 The battery is short circuited Repair the circuit Go to Step 4 3 1 Turn off the starter switch 2 Connect ECU connector 3 Turn on the starter switch 4 Set the transfer to the 2H mode I...

Page 430: ...ine 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...

Page 431: ...terminals B 48 1 and B 48 24 R 2 ohms The signal line circuit of the shift on the fly system is short circuited to GND Repair the circuit Go to Step 4 Go to Step 3 3 Is the resistance between terminal...

Page 432: ...r 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 s...

Page 433: ...tion 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...

Page 434: ...ter switch Is the battery voltage observed between terminals 14 and 46 or 34 and 46 The ECU has failed Replace the ECU Go to Step 2 Check the battery circuit Go to Step 2 2 Check that all the parts ar...

Page 435: ...WD 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 I...

Page 436: ...h is select to the 2WD position is 12 V observed between terminals 30 and 46 Go to Step 3 Repair the 4WD Auto Switch circuit Go to Step 4 3 When the transfer lever is shifted to the 4L position is bat...

Page 437: ...ONTROL SYSTEM TOD Chart B 2 The 4WD AUTO SWITCH circuit is short to battery Function of circuit Fail condition Even after the transfer mode is select from 2H to TOD Indicator lamp status Transfer posi...

Page 438: ...tor Is the continuity established between terminals B 49 14 and B 49 17 Go to Step 4 Replace TOD indicator lamp bulb Go to Step 7 4 Is the continuity established between terminals B 49 14 and B 49 6 G...

Page 439: ...short circuited Function of circuit 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 with...

Page 440: ...is short circuited between ECU and transfer Repair the circuit Go to Step 14 Go to Step 7 7 Turn off the starter switch When the transfer lever is shifted to the neutral position is the continuity es...

Page 441: ...d between transfer terminals M 27 4 and body The ECU has failed Replace the ECU Go to Step 14 The harness is broken between terminal M 27 4 and GND Repair the circuit Go to Step 14 14 Check that all t...

Page 442: ...64 Chart C 2 The 4H switch circuit is short circuited to GND Function of circuit Fail condition When the transfer lever is shifted to 4L the indicator lamp status is not changed Indicator lamp status...

Page 443: ...to Step 7 Replace TOD indicator lamp bulb Go to Step 23 7 Is the continuity established between terminals 14 and 19 Go to Step 8 Replace TOD indicator lamp bulb Go to Step 23 8 Is the continuity estab...

Page 444: ...hed between transfer connector terminals H 17 3 and B 48 9 Go to Step 20 Go to Step 19 19 When the transfer lever is shifted to the 4L position is the continuity established between transfer connector...

Page 445: ...oken or the battery is short circuited Function of circuit 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 mod...

Page 446: ...t battery is short circuited between ECU and transfer Repair the circuit Go to Step 13 Go to Step 7 7 Turn off the starter switch When the transfer lever is shifted to the high position is the continu...

Page 447: ...er is shifted to the high position is the continuity established between transfer connector terminals M 27 12 and GND Repair the transfer assembly Go to Step 13 Go to Step 13 13 Check that all the par...

Page 448: ...SYSTEM TOD 4B2 70 Chart D 2 The 4L switch circuit is short circuited to GND Function of circuit Fail condition The 4L mode is displayed even in the 2H or TOD Indicator lamp status Transfer position 2H...

Page 449: ...uity 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 B...

Page 450: ...he transfer assembly Go to Step 16 15 When the transfer lever is shifted to the high position is the continuity established between terminals M 27 12 and GND Repair the transfer assembly Go to Step 16...

Page 451: ...SYSTEM TOD Chart E 1 AXLE switch circuit wires are broken Function of circuit Fail condition Both the TOD and 4L modes are disabled The transition status is not removed Indicator lamp status Transfer...

Page 452: ...attery voltage observed between terminals 23 and 46 Go to Step 8 Go to Step 11 8 When the transfer lever is shifted to the neutral position between high and 4L is the battery voltage observed between...

Page 453: ...on each VSV Go to Step 17 Repair the circuit of replace the VSV Go to Step 19 17 Is the vacuum pressure supplied to the VSV Go to Step 18 Repair the vacuum system Go to Step 19 18 Can the single AXLE...

Page 454: ...switch circuit is short circuited to GND Function of circuit 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 remov...

Page 455: ...ved between terminals 23 and 46 Go to Step 9 Go to Step 11 9 When the transfer lever is shifted to the high position and 4WD Auto Switch selected to 4WD position is 0V observed between terminals 23 an...

Page 456: ...sure supplied to the VSV Go to Step 18 Repair the vacuum system Go to Step 19 18 Can the single AXLE switch enable and disable the continuity Repair the shift on the fly system refer to Section 4B1 Dr...

Page 457: ...4B2 79 DRIVE LINE CONTROL SYSTEM TOD Chart G The trouble codes are displayed Function of circuit Fail condition Indicator lamp status Transfer position D04RY00009...

Page 458: ...terminals B 48 7 and B 48 24 Go to Step 2 The ECU has failed Replace the ECU Go to Step 3 2 Is the self diagnostic connector short circuited Go to Step 3 Open the self diagnostic connector Go to Step...

Page 459: ...t 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 Indicator lamp...

Page 460: ...0 V observed between ECU terminal B 48 18 and B 48 24 Go to Step 3 Lighting SW circuit battery short Repair the circuit Go to Step 4 3 Connect ECU terminal While the lighting switch is pressed on and...

Page 461: ...according to Chart 1 2 Even if the 4WD Auto Switch is select to the 4WD position the 4WD mode is not active resulting in remarkable rear wheel spin D The transfer or wiring is imperfect D The shift on...

Page 462: ...ner braking is observed Function of circuit 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 phenome...

Page 463: ...to Step 6 Go to Step 11 6 1 Shift the transfer lever to the 2H position 2 Fully turn the steering to the left or right end and select the D range and start the creep run Does the tight corner braking...

Page 464: ...and start the creep run 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 2 Jack up the right fron...

Page 465: ...Chart 2 The 4WD mode is not active Function of circuit 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 sh...

Page 466: ...er to the 4L position fully turn the steering to the left or right end and start the creep run Does the tight corner braking occur Go to Step 5 Repair the transfer assembly Go to Step 7 5 1 Shift the...

Page 467: ...ly system generates gear noises The fuel economy is bad in the 2H mode Function of circuit Fail condition When the vehicle is run in the 2H mode the shift on the fly system generates gear noises or th...

Page 468: ...ep 5 4 When the 4WD Auto Switch is select to the 2WD position are the front axle gears correctly disengaged and when the left front tire is jacked up and turned is the front propeller shaft standstill...

Page 469: ...TOD Chart 4 The braking distance gets long even when the ABS is active Function of circuit Fail condition Enough deceleration is not obtained and the braking distance gets long even when the ABS is a...

Page 470: ...p 3 Repair the battery system Go to Step 4 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 Does the voltage with...

Page 471: ...d Repair 4C 21 Bushing Replacement 4C 21 Reassembly 4C 22 Shift On The Fly System 4C 24 Shift On The Fly System and Associated Parts 4C 24 Disassembly 4C 24 Inspection and Repair 4C 26 Main Data and S...

Page 472: ...ut the fasteners that require thread lockers or thread sealant UNLESS OTHERWISE SPECIFIED do not use supplemental coatings Paints greases or other corrosion inhibitors on threaded fasteners or fastene...

Page 473: ...s 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 incorrect Adjust the backlash Worn or chipped ring gea...

Page 474: ...mbly 8 ABS Sensor Ring 9 Inner Bearing 10 Oil Seal 11 Bolt 12 Wheel Pin Disassembly 1 Before disassembly jack up the front of vehicle and support frame with jack stands 2 Remove the two bolts from the...

Page 475: ...ing 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 411RS002 11 Remove bolt 12 If necessary replace the wheel pin in the...

Page 476: ...other abnormal conditions D Hub D Hub bearing D Bearing outer race D Disc D Oil seal Reassembly 1 Install wheel pin D Place hub on a wood workbench or a block of wood approx 6 by 6 to protect the whee...

Page 477: ...er race by driving it into the hub by using installer J 36828 and grip J 8092 901RW056 5 Install inner bearing Install the outer race by driving it into the hub by using installer J 36829 and grip J 8...

Page 478: ...N 4 4 5 5 lb Used bearing and New oil seal 11 8 17 7 N 2 6 4 0 lb If the measured bearing preload is outside the specifications adjust it by loosening or tightening the bearing nut 411RS011 9 Install...

Page 479: ...4C 9 DRIVE SHAFT SYSTEM Main Data and Specifications Torque Specifications E04RW00001...

Page 480: ...4C 10 DRIVE SHAFT SYSTEM Special Tools ILLUSTRATION TOOL NO TOOL NAME J 36827 Wrench Hub nut J 36829 Installer Inner bearing J 36828 Installer Outer bearing J 36830 Installer Oil seal...

Page 481: ...Disc Assembly 10 Wheel Pin 11 ABS Sensor Ring 12 Inner Bearing 13 Oil Seal Disassembly 1 Before disassembly select the 2WD position with the 4WD switch 2 Jack up the front of vehicle and support frame...

Page 482: ...3 D Place hub on a suitable work surface and remove the studs by using a hammer 411RS004 Inspection and Repair Make necessary correction or parts replacement if wear damage corrosion or any other abno...

Page 483: ...n scribe marks 1 and attach the hub to the disc then tighten the bolts to the specified torque Torque 103 N m 76 lb ft 411RS003 3 Use installer J 36829 and grip J 8092 then install the inner bearing b...

Page 484: ...aring 15 g 0 53 oz 411RS009 Legend 1 Inner Bearing 2 Hub 3 Outer Bearing 8 Install hub nut Turn to the place where there is a chamfer in the tapped hole to the outer side then attach the nut by using...

Page 485: ...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 joi...

Page 486: ...4C 16 DRIVE SHAFT SYSTEM Main Data and Specifications Torque Specifications E04RW001...

Page 487: ...4C 17 DRIVE SHAFT SYSTEM Special Tools ILLUSTRATION TOOL NO TOOL NAME J 36827 Wrench Hub nut J 36829 Installer Inner bearing J 36828 Installer Outer bearing J 36830 Installer Oil seal...

Page 488: ...eload 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...

Page 489: ...le Case and Differential 2 DOJ Case Assembly 3 Snap Ring 4 Bearing 5 Snap Ring 6 Oil Seal 7 Bracket 8 DOJ Case 9 Circlip 10 Bolt 11 Drive Shaft Joint Assembly 12 Snap Ring 13 Spacer 14 Ball 15 Snap Ri...

Page 490: ...ed end of the band 1 with a screwdriver or equivalent 412RS009 2 Remove band 3 Pry off circlip 1 with a screwdriver or equivalent 412RS010 4 Remove drive shaft joint assembly 5 Using snap ring pliers...

Page 491: ...OJ case assembly from the axle case 16 Remove snap ring and bearing 17 Remove snap ring and oil seal 18 Remove bracket Inspection and Repair Make necessary correction or parts replacement if wear dama...

Page 492: ...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 412RS017 9 Install another bellow...

Page 493: ...veral times to get to fit 17 Install the circlip 1 so that open ends are positioned away from the ball groove 412RS019 412RS020 Legend 1 Outer Case 2 Circlip 3 Open Ends 18 Install bellows Adjust the...

Page 494: ...g Internal 7 Inner Shaft 8 Needle Bearing 9 Clutch Gear 10 Sleeve 11 Housing 12 Front Axle Drive Shaft LH side with Bracket 13 Bolt 14 Actuator Assembly 15 Bolt Disassembly 1 Remove filler plug and ga...

Page 495: ...shaft by using snap ring pliers 412RW016 10 Remove inner shaft bearing by using a remover J 37452 and press NOTE Be careful not to damage the shaft 412RW015 11 Remove needle bearing from inner shaft...

Page 496: ...ormality in its gear part a slide with sleeve replace the shaft 420RS008 Inner Shaft Run Out With both end centers supported rotate the shaft slowly and measure deflection with a dial gauge Limit 0 5...

Page 497: ...il should be applied to the contact surface of gear Check the width of sleeve center groove Limit 7 1 mm 1 28 in 412RW022 Clutch Gear Condition Check and see that there is no wear damage cracking or a...

Page 498: ...nnect 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 State Port A Port B Function C 400 mmHg A P E D A P 400...

Page 499: ...n oil seal installer J 41693 and grip J 8092 412RS043 2 Force a new needle bearing into inner shaft by using a installer J 41694 and grip J 8092 412RS051 3 Place a new snap ring internal in inner shaf...

Page 500: ...n the actuator contact surface with the housing then Install and tighten shift position switch to specified torque Torque 39N m 29 lb ft 12 Apply liquid gasket to the contact surface on the actuator s...

Page 501: ...il 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 Cons...

Page 502: ...ME J 39378 Remover and Installer Front Axle mount bushing J 37452 Remover and Installer Inner shaft bearing J 26941 Remover Bearing needle J 2619 01 Hammer Sliding J 41693 Installer Oil seal J 41694 I...

Page 503: ...Front Propeller Shaft General Description Since the propeller shaft is balanced carefully welding or any other modifications are not permitted Alignment marks should be applied to each propeller shaft...

Page 504: ...ropeller Shaft with TOD 5 Coupling 6 LJ Constant Velocity Joint 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 n...

Page 505: ...ed to the constant velocity joint of the shaft 401RW051 Installation NOTE Never install the shaft assembly backwards Completely remove the black paint from the connecting surface of flange coupling on...

Page 506: ...YSTEM Disassembly Except TOD 4 4 401RW057 Legend 1 Sleeve Yoke 2 Seal 3 Tube Assembly 1 Apply alignment marks 1 on the sleeve yoke and tube assembly then remove sleeve yoke 401RW056 2 Remove seal 3 Re...

Page 507: ...ke 2 Spider 3 Snap Ring 4 Needle Roller Bearing 5 Grease Fitting 1 Apply alignment marks 1 on the yokes of the universal joint then remove snap ring 401RS028 2 Tap out the needle roller bearing by gen...

Page 508: ...ty joint Outside Diameter of Spider Pin Standard 17 00 mm 0 669 in Limit 16 90 mm 0 665 in 401RS007 Propeller Shaft Run out Support the ends of the propeller shaft on V blocks 2 and check for run out...

Page 509: ...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 motion...

Page 510: ...0 15 mm 0 006 in 401RW046 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 401RW045 3 If vibration is felt during the 4H AUTO dr...

Page 511: ...needle roller bearing cannot be installed smoothly if it is set at an incorrect angle with the flange and excessive hammering will damage the needle roller bearing 401RS012 4 Align setting marks 1 an...

Page 512: ...DRIVE SHAFT SYSTEM Reassembly Except TOD 4 4 401RW057 Legend 1 Sleeve Yoke 2 Seal 3 Tube Assembly 1 Discard used seal and install new one 2 Align the alignment marks and install tube assembly to sleev...

Page 513: ...mission M T A T A T with TOD Construction Hollow steel tube with yoke and spider type universal joints Hollow steel tube with constant velocty joints Outside diameter 40 0 mm 1 57 in 40 0 mm 1 57 in 4...

Page 514: ...propeller shaft before removal 401RW003 Rear Propeller Shaft and Associated Parts 401RW059 Legend 1 Bolt Nut and Washer 2 Rear Propeller Shaft 3 Bolt Nut and Washer Removal 1 Jack up the vehicle and s...

Page 515: ...t 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 prop...

Page 516: ...SHAFT SYSTEM Disassembly 401RW057 Legend 1 Sleeve Yoke 2 Seal 3 Tube Assembly 1 Apply alignment marks 1 on the sleeve yoke and tube assembly then remove sleeve yoke 401RW056 2 Remove seal 3 Remove tu...

Page 517: ...r with Grease Fitting 3 Snap Ring 4 Needle Roller Bearing 5 Grease Fitting 1 Apply alignment marks 1 on the yokes of the universal joint then remove snap ring 401RS028 2 Tap out the needle roller bear...

Page 518: ...oke 4 Flange Outside Diameter of Spider Pin Standard 17 00 mm 0 669 in Limit 16 90 mm 0 665 in 401RS007 Propeller Shaft Run out Support the ends of the propeller shaft on V blocks 2 and check for run...

Page 519: ...e needle roller bearing cannot be installed smoothly if it is set at an incorrect angle with the flange and excessive hammering will damage the needle roller bearing 401RS012 4 Align setting marks 1 a...

Page 520: ...4C 50 DRIVE SHAFT SYSTEM Reassembly 401RW057 Legend 1 Sleeve Yoke 2 Seal 3 Tube Assembly 1 Discard used seal and install new one 2 Align the alignment marks and install tube assembly to sleeve yoke...

Page 521: ...ngine 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 109...

Page 522: ...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...

Page 523: ...4D1 2 TRANSFER CASE STANDARD TYPE General Description M T model A07RW019...

Page 524: ...peration 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 usefu...

Page 525: ...g the following points 1 Install oil seal and apply engine oil to the oil seal outer surfaces 2 Apply the recommended grease BESCO L2 or equivalent to the oil seal lip 3 Use the oil seal installer J 3...

Page 526: ...on harness 7 Remove the right and left catalytic converter assemblies and exhaust pipe 8 Remove the transfer control lever knob 9 Remove the selector lever assembly Refer to Selector Lever in the Sect...

Page 527: ...xhaust pipe to exhaust manifold bolt to the specified torque Torque 67 N m 49 lb ft 4 Tighten the exhaust pipe flange bolt to the specified torque Torque 43 N m 32 lb ft 5 Tighten the propeller shaft...

Page 528: ...ange companion holder J 8614 11 to remove the end nut 262RW009 6 Remove the front and rear companion flange NOTE Use the universal puller to remove the rear companion flange 7 Remove control box assem...

Page 529: ...E 17430 or its equivalent to the transfer rear case fitting faces 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 sele...

Page 530: ...the 2WD 4WD actuator bolts to the specified torque Torque 19 N m 14 lb ft 9 Connect the actuator breather hose to actuator 10 Install control box assembly Torque 19 N m 14 lb ft 11 Install rear compa...

Page 531: ...the O ring 8 to the speedometer driven gear bushing 7 17 Install the driven gear to the speedometer driven gear bushing 7 18 Install the speedometer driven gear assembly to the transfer rear cover 19...

Page 532: ...Output Shaft Assembly 2 Rear Output Shaft 3 Bearing Snap Ring 4 Ball Bearing 5 Bearing Snap Ring 6 Ball 7 Speedometer Drive Gear 8 Ball Bearing 9 Transfer Rear Case with oil seal 1 Remove bearing snap...

Page 533: ...Remove transfer rear case with oil seal Inspection and Repair Refer to TRANSFER CASE ASSEMBLY in this section for inspection and repair Reassembly 1 Install transfer rear case with oil seal Oil seal r...

Page 534: ...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 9 Install bearing snap ring NOTE The...

Page 535: ...d 1 Transfer Case 2 Detent Ball Spring and Plug 3 Spring 4 Interlock Pin 5 4WD Indicator Switch 6 Shift Block 7 Spring Pin 8 Spring 9 Shift Arm 10 2WD 4WD Shift Rod 11 Spring Pin and Bridge 12 Select...

Page 536: ...rod 262RW022 6 Remove shift arm 7 Remove shift block 8 Remove 4WD indicator switch 9 Remove interlock pin 10 Remove spring use a magnetic tool to remove the interlock pin from the transfer case 262RS0...

Page 537: ...and shift arm 262RW012 7 Install select rod assembly 8 Install spring 9 Engage the High Low sleeve with the 4H side and install the interlock pin 4 in the proper direction 10 Install the shift rod 2W...

Page 538: ...D1 17 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 to the specified t...

Page 539: ...ti lash plate M T 14 Belleville Spring M T 15 Spacer M T 16 Sub Gear Snap Ring M T 17 Bearing Collar 18 Ball Bearing 19 Bearing Snap Ring 20 Snap Ring 21 Ball Bearing 22 Counter Gear 23 Sub Gear anti...

Page 540: ...nt companion flange temporarily 4 Use the Companion flange holder J 8614 11 and lock nut wrench J 37219 to remove the lock nut 226RW130 5 Remove the front companion flange 6 Remove snap ring 7 Remove...

Page 541: ...g pliers to expand the bearing snap ring and use a plastic hammer to tap the front output gear assembly free 262RS009 18 Remove bearing snap ring 19 Remove ball bearing 20 Remove bearing collar 21 Rem...

Page 542: ...bearing remover J 22912 01 to remove the ball bearing 226RS073 40 Remove spacer 41 Remove belleville spring 42 Remove sub gear anti lash plate 43 Remove counter gear Inspection and Repair 1 Make the...

Page 543: ...must be replaced Clutch hub spline play Standard 0 0 1 mm 0 0 004 in Limit 0 2 mm 0 008 in 226RS042 Bearings 1 Inspect the condition of all the needles and ball bearings Wash bearings thoroughly in a...

Page 544: ...alue exceeds the specified limit the 2WD 4WD synchronizer assembly must be replaced Block ring and insert clearance Standard 1 5 mm 0 059 in Limit 0 8 in 0 031 in 226RW142 Clutch Hub and Insert Cleara...

Page 545: ...an the specified limit 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...

Page 546: ...output shaft oil seal 2 replacement 1 Remove the oil seal from the transfer case 2 Apply engine oil to the oil seal outer surfaces 3 Apply recommended grease BESCO L2 or equivalent to the oil seal lip...

Page 547: ...r end of the piano wire 4 to a spring balancer 3 Measure the sub gear preload Preload 59 98 N 13 22 lb 226RS075 9 Install ball bearing 10 Install snap ring 11 Install the counter gear assembly to the...

Page 548: ...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 gr...

Page 549: ...nstall the needle bearing collar together with the front output gear 262RS014 31 Install ball bearing 32 Install bearing snap ring and select a snap ring that will allow the minimum axial play Clearan...

Page 550: ...use a bench press to install the ball bearing to the input shaft 265RS003 38 Install plate 39 Install ball 40 Install bearing collar 41 Install needle bearing 42 Install transfer input gear 43 Install...

Page 551: ...4D1 30 TRANSFER CASE STANDARD TYPE 50 Install ball bearing use a suitable drift and hammer to install the ball bearing 226RS079 51 Install bearing snap ring...

Page 552: ...een 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 sh...

Page 553: ...4D1 32 TRANSFER CASE STANDARD TYPE E07RW009...

Page 554: ...TRANSFER CASE STANDARD TYPE 4D1 33 E07RW010...

Page 555: ...r case oil seal installer J 37219 Mainshaft nut wrench J 37223 Rear output shaft and bearing installer J 39209 Punch end nut ILLUSTRATION PART NO PART NAME J 38594 Front output shaft oil seal installe...

Page 556: ...TRANSFER CASE STANDARD TYPE 4D1 35 ILLUSTRATION PART NO PART NAME J 37487 Puller J 8092 Driver handle...

Page 557: ...Clutch Cam 4D2 38 Disassembled View 4D2 38 Reassembly 4D2 38 Main Data and Specifications 4D2 40 Special Tools 4D2 42 Service Precaution WARNING THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM SRS R...

Page 558: ...2 TRANSFER CASE TOD Transfer Case Assembly Removal F07RW025 1 Disconnect the battery cable 2 Remove transfer protector 3 Remove rear propeller shaft 4 Remove front propeller shaft 5 Remove center cons...

Page 559: ...ight 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 c...

Page 560: ...4D2 4 TRANSFER CASE TOD 3 Tighten the transfer case bolts see the figure below 261RW004 4 Tighten propeller shaft bolt Torque 63 N m 46 lb ft...

Page 561: ...ple 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 sea...

Page 562: ...on flange O ring washer and nuts to the transfer in this order 4 Using the flange holder J 8614 11 set the end nut Torque 167 N m 123 lb ft 5 Using the punch J 39209 stake the end nut at two places NO...

Page 563: ...he battery cable 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 In...

Page 564: ...us 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 thes...

Page 565: ...Transfer Cover Assembly 7 Rear Companion Flange Disassembly 1 Remove the drain plug from the transfer case and drain the oil 2 Disconnect the 4H and 4L switch and grounding cable 3 Remove the clip fix...

Page 566: ...ecess position of the pin 261RW016 8 Remove the offset lever 261RW017 9 Remove the sixteen bolts and detach the transfer cover assembly from the transfer cable assembly NOTE When removing the transfer...

Page 567: ...ng 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 Torqu...

Page 568: ...ly Disassembled View 261RW007 Legend 1 Coil Assembly 2 Snap Ring 3 Ball Bearing 4 Speed Gear and Tone Wheel 5 Ball Bearing 6 Transfer Cover Assembly 7 Front and Rear Speed Sensors Disassembly 1 Using...

Page 569: ...ack 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 261RW042 5 Using a terminal pull...

Page 570: ...y 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 261RW035 4...

Page 571: ...rminal 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...

Page 572: ...Washer 3 Armature Plate 4 Snap Ring 5 Wave Spring 6 Cam Pulley 7 Cam Ball 8 Cam and Coil Housing 9 Thrust Bearing Disassembly 1 Remove thrust bearing 2 Remove cam and coil housing NOTE When the cam an...

Page 573: ...ley 5 Remove wave spring 6 Using snap ring pliers remove the snap ring NOTE Pay attention not to damage the snap ring 266RW009 7 Remove the armature plate 8 Remove the insulator washer 9 Remove the cl...

Page 574: ...Hose 3 Oil Pump Assembly 4 Thrust Washer 5 Mechanical Lock Hub 6 Lock up Sleeve 7 Lock up Fork 8 Chain 9 Lower Drive Sprocket 10 Front Tone Wheel 11 Drive Sprocket 12 Sprocket Spacer Disassembly 1 Re...

Page 575: ...l 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...

Page 576: ...Assembly 2 Detent Spring 3 Front Output Shaft 4 Reduction Hub 5 Output Shaft 6 Lock up Roll Assembly 7 Spring Pin 8 Spring Pin 9 Reduction Fork 10 Cam Assembly 11 Snap Ring 12 Washer 13 Cam 14 Cam Pi...

Page 577: ...ilot block assembly and cam assembly 5 Remove the spring pin that fixes the reduction hub together 261RW019 6 Remove the spring pin that fixes the reduction fork 261RW020 7 Remove the reduction fork 8...

Page 578: ...3 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 18 Rem...

Page 579: ...Case Disassembled View 265RW002 Legend 1 Transfer Case 2 Ball Bearing 3 Ring Gear 4 Snap Ring 5 Input Shaft and Carrier Assembly 6 Snap Ring 7 Ball Bearing 8 Spring Ring 9 Thrust Plate 10 Carrier Asse...

Page 580: ...the gap on the carrier assembly 261RW040 3 While opening the snap ring remove the input shaft ball bearing carrier assembly and thrust plate from the transfer case 261RW037 4 Remove the snap ring fro...

Page 581: ...ap ring from the carrier assembly 265RW006 10 Remove the circular hub 11 Remove the snap ring before the ring gear 261RW025 12 Using the special tool J 42806 remove the ring gear NOTE Removing the rin...

Page 582: ...n 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 surfa...

Page 583: ...0 275 0 279 in Allowable limit 6 3 mm 0 248 in 261RW027 Bearing Check the profile of the needle roller ball and thrust bearings Wash the bearings with clean detergent completely and dry with air NOTE...

Page 584: ...imit 130 N 13 3 kg 261RW041 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 re...

Page 585: ...f defective replace the parts 4H and 4L switches 266RW016 The Parts 4H and 4L Switch D Check the continuity of 4H and 4L switch 261RW003 261RW049 Switch Stroke 4H Switch Signal 4L Switch Signal The co...

Page 586: ...Gear 4 Snap Ring 5 Input Shaft and Carrier Assembly 6 Snap Ring 7 Ball Bearing 8 Spring Ring 9 Thrust Plate 10 Carrier Assembly 11 Snap Ring 12 Circular Hub Reassembly 1 Remove the oil seal from the t...

Page 587: ...ol J 42809 press fit the ring gear Pay attention to the following points D Identify the correct direction of gear D Do not damage the gear D Do not press fit the ring gear slantingly D Press fit the r...

Page 588: ...l bearing to the input shaft so that the 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 14 Using the sna...

Page 589: ...ront Output Shaft 4 Reduction Hub 5 Output Shaft 6 Lock up Roll Assembly 7 Spring Pin 8 Spring Pin 9 Reduction Fork 10 Cam Assembly 11 Snap Ring 12 Washer 13 Cam 14 Cam Pilot Block 15 Shifter Shaft As...

Page 590: ...ssembly to the shifter lever shaft and fix the assembly with the snap ring 261RW021 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 26...

Page 591: ...shifter shaft assembly 261RW019 10 Tighten the cam pilot block set bolts to the specified torque Torque 12 N m 104 lb in 11 Tighten the detent spring to the specified torque Torque 16 N m 12 lb ft 26...

Page 592: ...her 5 Mechanical Lock Hub 6 Lock up Sleeve 7 Lock up Pork 8 Chain 9 Lower Drive Sprocket 10 Front Tone Wheel 11 Drive Sprocket 12 Sprocket Spacer Reassembly 1 Install oil pump 2 Attach the hose and st...

Page 593: ...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...

Page 594: ...e Spring 6 Cam Pulley 7 Cam Ball 8 Cam and Coil Housing 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...

Page 595: ...TOD 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 housi...

Page 596: ...nge 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...

Page 597: ...4D2 41 TRANSFER CASE TOD E07RW012...

Page 598: ...older J 42804 Rear Oil Seal Installer J 39209 Punch J 42805 Bearing Remover J 2619 01 Slide Hammer J 22912 01 Bearing Remover ILLUSTRATION TOOL NO TOOL NAME J 42806 Ring Gear Replacer J 42807 Front Ou...

Page 599: ...uble Codes 5A 23 Diagnosis By ABS Warning Light Illumination Pattern 5A 24 Diagnostic Trouble Codes DTCs 5A 24 Chart B 1 With the key in the ON position Before starting the engine Warning light W L is...

Page 600: ...HE SRS COMPONENTS OR THE SRS WIRING REFER TO THE SRS SERVICE INFORMATION FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT PERSONAL INJURY OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS...

Page 601: ...sists of ABS control circuits fault detector and a fail safe It drives the hydraulic unit according to the signal from each sensor cancelling ABS to return to normal braking when a malfunction has occ...

Page 602: ...s are connected mechanically This tendency is noticeable particularly on roads with low friction coefficient and the ABS control is adversely affected The G sensor judges whether the friction coeffici...

Page 603: ...sconnected with the ignition ON D EHCU of the Anti lock Brake System are not separately serviceable and must be replaced as assemblies Do not disassemble any component which is designated as non servi...

Page 604: ...even though the trouble code is stored NOTE Illumination of the ABS warning light indicates that anti lock braking is no longer available Power assisted braking without anti lock control is still ava...

Page 605: ...mponent are properly mounted Was this step finished Finished Go to Step 5 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 sw...

Page 606: ...OL SYSTEM Tech 2 Scan Tool From 98 MY Isuzu dealer service departments are recommended to use Tech 2 Please refer to Tech 2 scan tool user guide 901RW257 Legend 1 PCMCIA Card 2 SAE 16 19 Adaptor 3 DLC...

Page 607: ...the DLC cable 3 3 Connect the DLC cable to the Tech 2 4 4 Make sure the vehicle ignition is off 5 Connect the Tech 2 SAE 16 19 adapter to the vehicle DLC connector 821RW021 6 The vehicle ignition turn...

Page 608: ...5A 10 BRAKE CONTROL SYSTEM 060RX064...

Page 609: ...Low High To be Low usually Transfer Monitor TOD 2 Wheel Drive 4 Wheel Drive When 2WD 2 Wheel Drive When 4WD 4 Wheel Drive Off Road Switch Transmission Input Active Inactive When shift lever position...

Page 610: ...CV 20 21 more than 200mV Turn wheel at 1RPS 5 FR speed sensor OFF 2km 4 5 1 3k to 1 9km Internal Resistance OFF 200km 4 15 more than 100km Insulation Resistance OFF 200mACV 4 5 more than 200mV Turn wh...

Page 611: ...5A 13 BRAKE CONTROL SYSTEM Circuit Diagram D08RW033...

Page 612: ...5A 14 BRAKE CONTROL SYSTEM D08RW034...

Page 613: ...5A 15 BRAKE CONTROL SYSTEM D08RW035...

Page 614: ...5A 16 BRAKE CONTROL SYSTEM Connector List D05RW002...

Page 615: ...5A 17 BRAKE CONTROL SYSTEM D05RW003...

Page 616: ...n D08RW369 Legend 1 F 2 2 F 3 3 I 9 4 C 63 5 H 7 H 8 H 24 H 25 6 B 25 7 C 16 8 Fuse Box 9 B 13 or B 14 10 C 13 11 H 10 H 11 12 C 41 13 H 41 H 42 14 C 4 15 C 85 16 Relay Fuse Box X 15 17 H 12 H 15 H 16...

Page 617: ...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 t...

Page 618: ...Was the Chart A 1 finished Go to Step 3 Go to Step 2 3 Reconnect all components ensure all components are properly mounted Was this step finished Repeat the Basic diagnostic flow chart Go to Step 3 C...

Page 619: ...grounded properly Replace EHCU Go to Step 9 Correct Go to Step 9 9 Reconnect all components ensure all components are properly mounted Was this step finished Repeat the Basic diagnostic flow chart Go...

Page 620: ...me of shift down or clutch operation D At the time of low m drive ice or snow road or rough road drive D At the time of high speed turn D At the time of passing curb D At the time of operating electri...

Page 621: ...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 disconnecte...

Page 622: ...ted while driving Diagnostic trouble codes are stored Display diagnostic trouble codes and diagnose on a code basis according to the flow charts Diagnostic Trouble Codes DTCs When the warning light in...

Page 623: ...ng 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...

Page 624: ...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 OF...

Page 625: ...nector Go to Step 5 5 Reconnect all components ensure all components are properly mounted Was this step finished Repeat the Basic diagnostic flow chart Go to Step 5 Chart B 2 EHCU Abnormality DTC 14 S...

Page 626: ...1 1 Turn the key off 2 Disconnect EHCU and PCM connector Is there continuity between EHCU connector terminals 25 and ground Go to Step 2 Repair harness or connector Go to Step 3 2 1 Connect EHCU conne...

Page 627: ...o Step 5 Chart B 6 Abnormal Transmission Input DTC 23 Step Action Yes No 1 1 Turn the key off 2 Disconnect EHCU connector Is there continuity between EHCU connector terminal 6 to 15 Gear position P A...

Page 628: ...ep 3 2 Is the TOD ECU or 4WD controler normal Replace EHCU Go to Step 3 Repair or replace TOD ECU or 4WD contrder Go to Step 3 3 1 Reconnect all components ensure all components are properly mounted 2...

Page 629: ...U Connector Pin out Checks perfomed Go to Step 2 Go to EHCU Connector Pin out Checks 2 Is the EHCU connector free from damage or corrosion Go to Step 3 Repair the connector Repeat the Basic Diagnostic...

Page 630: ...ed Go to Step 2 Go to EHCU Connector Pin out Checks 2 Is the EHCU connector free from damage or corrosion Go to Step 3 Repair the connector Repeat the Basic Diagnostic Flow Chart 3 1 Replace the EHCU...

Page 631: ...DTC 51 Step Action Yes No 1 1 Turn the key off 2 Disconnect EHCU connector 3 Measure the resistance between EHCU connector terminals 20 and 21 Is the resistance between 1 3k and 1 9k ohms Check for fa...

Page 632: ...unted 2 Clear diagnostic trouble code Was this step finished Repeat the Basic diagnostic flow chart Go to Step 3 Chart B 18 RL Speed Sensor Disconnection DTC 53 Step Action Yes No 1 1 Turn the key off...

Page 633: ...nd EHCU 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 connector Is the sensor resistance...

Page 634: ...e sensor Go to Step 6 4 Damage and powdered iron sticking to sensor sensor ring Go to Step 5 Repair Go to Step 6 5 Is sensor output normal Chart C 2 or TC 2 Check for faults in harness between speed s...

Page 635: ...ce sensor Go to Step 6 4 Damage and powdered iron sticking to sensor sensor ring Go to Step 5 Repair Go to Step 6 5 Is sensor output normal Chart C 2 or TC 2 Check for faults in harness between speed...

Page 636: ...e sensor Go to Step 6 4 Damage and powdered iron sticking to sensor sensor ring Go to Step 5 Repair Go to Step 6 5 Is sensor output normal Chart C 2 or TC 2 Check for faults in harness between speed s...

Page 637: ...ce sensor Go to Step 6 4 Damage and powdered iron sticking to sensor sensor ring Go to Step 5 Repair Go to Step 6 5 Is sensor output normal Chart C 2 or TC 2 Check for faults in harness between speed...

Page 638: ...djust or repair Go to Step 8 Go to Step 7 7 Is the check wiring between sensor and EHCU normal Replace EHCU Go to Step 8 Repair and perform system self check Go to Step 8 8 1 Reconnect all components...

Page 639: ...between EHCU connector terminals while turning FL wheel at a speed of 1 RPS Is voltage between EHCU connector terminals 20 and 21 under 200 mV Go to Step 2 Ok Go to Step 3 2 1 Disconnect the wheel sp...

Page 640: ...e all components are properly mounted Was this step finished Repeat the Basic diagnostic flow chart Go to Step 3 Chart C 1 3 RL Sensor Output Inspection Procedure Step Action Yes No 1 1 Turn the key o...

Page 641: ...y mounted Was this step finished Repeat the Basic diagnostic flow chart Go to Step 3 Chart TC 1 Sensor Output Inspection Procedure Use TECH 2 Step Action Yes No 1 1 Connect TECH 2 2 While driving the...

Page 642: ...e Disconnected harness Repair SW and harness Go to Step 6 4 Turn the key on and measure the voltage between EHCU connector terminal 6 and 15 Is there more than 9 6V when the gear position is 1 2 R Bat...

Page 643: ...ther 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 In...

Page 644: ...KE CONTROL SYSTEM Special Tools ILLUSTRATION TOOL NO 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...

Page 645: ...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 DEPLOYM...

Page 646: ...ve brake pipes D After disconnecting brake pipe cap or tape the openings of the brake pipe to prevent the entry of foreign matter 5 Remove hydraulic unit fixing nuts Installation To install follow the...

Page 647: ...move G sensor assembly 3 Inspection and Repair Refer to Chart B 5 in this Section Installation 1 Install G sensor assembly 3 D Care should be taken so that the G sensor is not installed in the wrong d...

Page 648: ...de 3 Sensor Cable Fixing Bolt Lower side 4 Sensor Cable Fixing Bolt Sensor side 5 Speed Sensor Removal 1 Remove speed sensor connector 2 Remove sensor cable fixing bolt Upper side 3 Remove sensor cabl...

Page 649: ...nd 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 tor...

Page 650: ...d sensor cable for a short or an open and replace with a new one if necessary To check for cable short or open bend or stretch the cable while checking for continuity 4 Check the sensor ring for damag...

Page 651: ...Fluid Reservoir Tank 5C 20 Fluid Reservoir Tank and Associated Parts 5C 20 Removal 5C 20 Installation 5C 20 Master Cylinder Assembly 5C 21 Master Cylinder Assembly and Associated Parts 5C 21 Removal 5...

Page 652: ...BLE AIR BAG DEPLOYMENT PERSONAL INJURY OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS CAUTION Always use the correct fastener in the proper location When you replace a fastener use ONLY the exact part numbe...

Page 653: ...hen drawn from the booster through the vacuum check valve to the vacuum source CAUTION 1 If any hydraulic component is removed or disconnected it may be necessary to bleed all or part of the brake sys...

Page 654: ...W001 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 ca...

Page 655: ...ly loaded vehicle requires more braking effort 3 Wheel Alignment Misalignment of the wheels particularly in regard to excessive camber and caster will cause the brakes to pull to one side Brake Fluid...

Page 656: ...k per instructions If not within specifications replace or machine the rotor Parallelism not within specifications Check per instructions If not within specifications replace or machine the rotor Whee...

Page 657: ...lace Piston in the disc brake caliper sticking Replace piston seals Brake pads sticking in caliper Clean Return spring weakened Replace Parking brake binding Overhaul the parking brakes and correct Fr...

Page 658: ...or replace Level of brake fluid in reservoir too low Replenish and bleed Air in hydraulic circuit Bleed Disc brake caliper faulty Clean or replace Water or oil on brake pads Clean or replace Brake pa...

Page 659: ...ir from the hydraulic brake system whenever air is introduced into the hydraulic system It may be necessary to bleed the hydraulic system at all four brakes if air has been introduced through a low fl...

Page 660: ...e 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 re...

Page 661: ...hose fittings at both ends 4 Disconnect brake pipe 5 Remove clip 6 Remove bolt and gasket 7 Remove hose Installation To install follow the removal steps in the reverse order noting the following poin...

Page 662: ...ign 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 Installation To install follow the removal steps in the reverse or...

Page 663: ...rial off the pipe fittings at both ends 4 Remove brake pipe 1 330RW001 5 Remove plastic clip 2 330RW002 Installation To install follow the removal steps in the reverse order noting the following point...

Page 664: ...r and turn on the brake system warning light on the instrument panel in the event of a front or rear system malfunction The valve and switch are so designed that the switch will latch in the warning p...

Page 665: ...5C 15 POWER ASSISTED BRAKE SYSTEM Main Data and Specifications Torque Specifications E05RW001...

Page 666: ...at 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 nu...

Page 667: ...er 7 Remove stoplight switch connector 8 Remove return spring 9 Remove snap pin 10 Remove pin 11 Remove nut 12 Remove fulcrum pin 13 Remove brake pedal Installation 1 Install brake pedal 2 Install ful...

Page 668: ...0RW004 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 0...

Page 669: ...5C 19 POWER ASSISTED BRAKE SYSTEM Main Data and Specifications General Specifications Pedal free play 6 10 mm 0 23 0 39 in Pedal Height 208 218 mm 819 8 58 in Torque Specifications E05RW002...

Page 670: ...fluid from the fluid reservoir 1 Disconnect electrical connector 2 Remove retainer 1 330RW004 3 Remove fluid reservoir and the fluid lever sensor built into the fluid reservoir The fluid level sensor...

Page 671: ...of the piston is the surface on which seals are to slide Care should be taken to keep the surface free of cuts and dents 1 Disconnect electrical connector 2 Remove brake pipes after disconnecting the...

Page 672: ...ld be a pressure increase of 0 5 kg cm or more 330RW009 NOTE When checking the front or primary side be sure to mount the master cylinder plug in the rear or secondary port 0 Line 5 Line Apply air pre...

Page 673: ...e pipe to the specified torque Master cylinder side Torque 12 N m 104 lb in Others Torque 16 N m 12 lb ft 6 Connect electrical connector Main Data and Specifications General Specifications Type Dual c...

Page 674: ...C 24 POWER ASSISTED BRAKE SYSTEM Special Tools ILLUSTRATION TOOL NO TOOL NAME J 39242 Primary Piston Holder including master cylinder attachment and master cylinder plug J 24460 01 Radiator Cap Tester...

Page 675: ...isconnecting the vacuum hose in advance If any negative pressure remains in the vacuum booster the piston may possibly come out when the master cylinder is being removed letting the brake fluid run ou...

Page 676: ...ure 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 331RS003 3 S...

Page 677: ...assembly in vacuum booster front shell Then install the retainer 7 Install vacuum booster fixing nut and tighten the specified torque Torque 21 N m 16 lb ft 8 Install yoke clevis 9 Connect vacuum hos...

Page 678: ...eal Assembly 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...

Page 679: ...3 Install 2 gaskets and spacer 4 Install filter 5 Install silencer 6 Install valve body guard 7 Install retainer 8 Install lock nut and tighten to the specified torque Torque 20 N m 15 lb ft 9 Instal...

Page 680: ...al Specifications 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...

Page 681: ...5C 31 POWER ASSISTED BRAKE SYSTEM Special Tools ILLUSTRATION TOOL NO TOOL NAME J 39216 Push Rod Gauge J 23738 A Vacuum Pump J 39241 Push Rod Support...

Page 682: ...orn 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 itsel...

Page 683: ...ty stands 1 Remove wheel and tire assembly refer to Wheels and Tires System in Section 3E 2 Remove lock bolt 1 302RW004 3 Remove caliper assembly and support the caliper assembly so that the brake hos...

Page 684: ...t damage the flexible hose by twisting or pulling it 302RS008 4 Install lock bolt 5 and tighten the bolt to the specified torque Torque 74 N m 54 lb ft 302RW007 5 Install wheel and tire assembly refer...

Page 685: ...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 The rotor thickness must not...

Page 686: ...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 Refin...

Page 687: ...mbly 5 Clip 6 Support Bracket with Pad Assembly 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...

Page 688: ...support bracket 9 Remove pad assembly with shim and mark the lining locations if they are to be reinstalled 10 Remove clip Installation 1 Install clip 302RS005 2 Install pad assembly with shim and ap...

Page 689: ...ll 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 Torque 35 N m...

Page 690: ...Bolt 2 Lock Bolt 3 Bleeder with Cap 4 Caliper Body 5 Dust Boot Guide Bolt and Lock Bolt 6 Piston Seal 7 Piston 8 Dust Boot Piston 9 Dust Boot Ring Disassembly 1 Remove guide bolt 2 Remove lock bolt 3...

Page 691: ...any other abnormal conditions are found through inspection Check the following parts D Rotor D Cylinder body D Cylinder bore D Piston D Guide bolt lock bolt D Support bracket NOTE The piston seal boot...

Page 692: ...the dust boot 302RS020 7 Install guide bolt and lock bolt dust boot 8 Install lock bolt and guide bolt and tighten the bolt to the specified torque Torque 74 N m 54 lb ft 9 Install the dust boot on th...

Page 693: ...s General Specifications Type Floating pin slide Pad dimension 55 cm 8 52 in Adjusting method Self adjusting Piston diameter 60 33 mm 2 38 in Disc type Ventilated Disc thickness 26 mm 1 02 in Disc eff...

Page 694: ...ad 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...

Page 695: ...e safety stands 1 Remove wheel and tire assembly refer to Wheels and Tires System in Section 3E 2 Remove lock bolt 1 306RW002 3 Remove caliper assembly and support the caliper assembly so that the bra...

Page 696: ...not damage the flexible hose by twisting or pulling it 302RS008 4 Install lock bolt 5 and tighten the bolt to the specified torque Torque 44 N m 32 lb ft 5 Install wheel and tire assembly refer to Wh...

Page 697: ...asurement 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 The rotor thickness must not var...

Page 698: ...he 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...

Page 699: ...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 306RW008...

Page 700: ...ontacting surfaces of the inner shims 5 Wipe off extruded grease after installing 306RW011 Legend 5 Inner Shim 6 Wear indicator 3 Install support bracket and tighten the bolt 7 to the specified torque...

Page 701: ...o put the hooked edge of the flexible hose end into the anti rotation cavity then tighten the I bolt 9 to the specified torque Torque 35 N m 26 lb ft 302RW017 7 Install the wheel and tire assembly ref...

Page 702: ...d 1 Guide Bolt 2 Lock Bolt 3 Bleeder with Cap 4 Caliper Body 5 Piston Seal 6 Piston 7 Dust Boot Piston 8 Dust Boot Ring 9 Dust Boot Guide Bolt and Lock Bolt Disassembly 1 Remove guide bolt 2 Remove lo...

Page 703: ...n or any other abnormal conditions are found through inspection Check the following parts D Rotor D Cylinder body D Cylinder bore D Piston D Guide bolt lock bolt D Support bracket NOTE The piston dust...

Page 704: ...the dust boot 302RS020 7 Install guide bolt and lock bolt dust boot 8 Install lock bolt and guide bolt and tighten the bolt to the specified torque Torque 74 N m 54 lb ft 9 Install the dust boot on t...

Page 705: ...General Specifications Type Floating pin slide Pad dimension 33 cm 5 11 in Adjusting method Self adjusting Piston diameter 41 3 mm 1 63 in Disc type Ventilated Disc thickness 18 mm 0 71 in Disc effec...

Page 706: ...quire 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 oth...

Page 707: ...he 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 for...

Page 708: ...ont Cable Parking Brake Lever Front Cable and Associated Parts 311RW001 Legend 1 Parking Brake Lever 2 Bolt 3 Adjusting Nut 4 Equalizer 5 Parking Brake Front Cable 6 Switch Connector Removal 1 Remove...

Page 709: ...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 bolt t...

Page 710: ...embly 9 Rotor Drum 10 Rear Wheels 11 Cable Fixing Bolt 12 Clip 13 Clip 14 Clip 15 Rear Cable Removal 1 Remove adjusting nut 2 Remove rear wheels 3 Remove caliper assembly remove two bolts to remove th...

Page 711: ...assembly and after installation of the shoe and cable assembly apply the special grease included in the repair kit to the portions indicated in the illustration 308RS002 4 Install return spring lower...

Page 712: ...h 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 ord...

Page 713: ...cations 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 pul...

Page 714: ...tion 6A 32 Cylinder Head 6A 35 Removal 6A 35 Installation 6A 35 Valve Stem Oil Controller Valve Spring and Valve Guide 6A 37 Removal 6A 37 Installation 6A 37 Piston Piston Ring and Connecting Rod 6A 3...

Page 715: ...VICE INFORMATION FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT PERSONAL INJURY OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS CAUTION Always use the correct fastener in the proper l...

Page 716: ...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 employ...

Page 717: ...e engine is running Condition Possible cause Correction Spark jumps across gap Spark plug defective Clean adjust spark gap or replace Ignition timing incorrect Refer to Ignition System Fuel not reachi...

Page 718: ...pression 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...

Page 719: ...orrect or replace Intake Air Temperature sensor defective Replace Ion sensing module cable broken or poor connections Correct or replace Ion sensing module defective Replace Vehicle Speed Sensor circu...

Page 720: ...Engine lacks power Spark plugs fouled Clean Fuel injectors defective Replace Mass Airflow Sensor or Intake Airflow Sensor circuit defective Correct or replace Manifold Absolute Pressure MAP Sensor or...

Page 721: ...or shorted Correct or replace Ion sensing module Circuit open or poor connections Correct or replace Ion sensing module defective Replace IAT Sensor defective Replace Hesitation at high speeds Fuel t...

Page 722: ...ace Mass Airflow Sensor circuit open or poor connections Correct or replace Mass Airflow Sensor defective Replace MAP Sensor cable broken or poor connections Correct or replace MAP Sensor defective Re...

Page 723: ...rcuit Throttle Position Sensor cable broken or poor connections Correct or replace Throttle Position Sensor defective Replace Mass Airflow Sensor not working normally Replace Manifold Absolute Pressur...

Page 724: ...abnormal Adjust to recommended pressures Brake drag Adjust Clutch slipping Adjust or replace Level of oil in engine crankcase too high Correct level of engine oil Exhaust Gas Recirculation Valve defe...

Page 725: ...replace g Connecting rod bearing seized Replace connecting rod bearings and crankshaft or regrind crankshaft pin and install the undersize bearing Troubleshooting Procedure Abnormal noise stops when t...

Page 726: ...eized 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 noise occurs when...

Page 727: ...ottle Position Sensor defective Replace Throttle Position Sensor connector poor connections Reconnect Vehicle Speed Sensor cable poor connections or defective Correct or replace Vehicle Speed Sensor l...

Page 728: ...5 ENGINE MECHANICAL Condition Correction Possible cause Trouble in cylinder head parts Carbon deposits in combustion chamber Remove carbon Carbon deposit on valve valve seat and valve guide Remove car...

Page 729: ...lace oil seal Oil leaking into combustion chambers due to poor seal in valve Valve stem oil seal defective Replace chambers due to oor seal in valve system Valve stem or valve guide worn Replace valve...

Page 730: ...re gauge defective Correct or replace Crankshaft bearing or connecting rod bearing worn Replace Oil contamination Wrong oil in use Replace with correct engine oil Oil filter clogged Replace oil filter...

Page 731: ...onnect properly Heated oxygen sensor lead wire shorted Correct Heated oxygen sensor circuit open Correct or replace Deterioration of engine coolant temperature sensor internal element Replace Engine c...

Page 732: ...linder head cover 5 Ignition coil connector and ignition coil D Disconnect the three connectors from the ignition coils D Remove harness bracket bolt on cylinder head cover D Remove fixing bolts on ig...

Page 733: ...ection harness bracket and tighten bolt to the specified torque Torque 9 N m 80 lb in 3 Connect ignition coil connector and ignition coil then tighten bolt to the specified torque Torque 4 N m 35 lb i...

Page 734: ...head cover D Clean the sealing surface of cylinder head and cylinder head cover to remove oil and sealing materials completely Apply sealant TB 1207B or equivalent bead diameter 2 3 mm at eight place...

Page 735: ...n common chamber and remove EGR valve assembly 9 Remove two bolts from common chamber rear side for remove fuel hose bracket 10 Remove common chamber four bolts and four nuts then remove the common ch...

Page 736: ...ustration 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 Conne...

Page 737: ...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 Installation 1...

Page 738: ...8 Remove exhaust manifolds eight fixing nuts and the exhaust manifold Installation 1 Install exhaust manifold and tighten bolts to the specified torque Torque 52 N m 38 lb ft Torque 44 N m 33 lb ft T...

Page 739: ...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...

Page 740: ...mbly using J 8614 01 crankshaft holder hold crankshaft pulley remove center bolt then the pulley 11 Remove right side timing belt cover then left side timing belt cover 12 Remove lower timing belt cov...

Page 741: ...ment Mark on Timing Belt 014RW006 Legend 1 Timing Belt 2 Engine Rotation Direction 3 Cylinder Head Side 1 Install timing belt 1 Align groove of crankshaft timing pulley with mark on oil pump Align the...

Page 742: ...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 NOTE It is...

Page 743: ...r Lower 020RW003 Legend 1 Timing Belt Cover 2 Rubber Bushing 3 Sealing Rubber 4 Cylinder Body 4 Install crankshaft pulley using J 8614 01 hold the crankshaft pulley and tighten center bolt to the spec...

Page 744: ...then install drive belt to normal position 850RW001 Legend 1 Crankshaft Pulley 2 Cooling Fan Pulley 3 Auto Tensioner 4 Generator 5 Air Conditioner Compressor 6 Power Steering Oil Pump 7 Idle Pulley 8...

Page 745: ...aft bearing caps 014RW027 7 Remove camshaft assembly 8 Remove fixing bolt for camshaft drive gear pulley 9 Remove three fixing bolts from camshaft drive gear retainer then camshaft drive gear assembly...

Page 746: ...o 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 Int...

Page 747: ...tration Torque 10 N m 89 lb in 014RW031 5 Install cylinder head cover RH D Refer to installation procedure for CYLINDER HEAD COVER RH in this manual 6 Install cylinder head cover LH D Refer to install...

Page 748: ...is manual 10 Remove cylinder head assembly A Loosen head bolts in reverse of tightening sequence B Remove cylinder head assembly 014RW028 Legend 1 Cylinder Head 2 Cylinder Head Bolt 3 Camshaft Install...

Page 749: ...for Common Chamber in this manual 3 Install cylinder head cover RH D Refer to installation procedure for Cylinder Head Cover RH in this manual 4 Install cylinder head cover LH D Refer to installation...

Page 750: ...sing J 37281 oil controller remover remove each valve stem oil controller 8 Remove valve guide using J 37985 valve guide replacer Installation 1 Install valve guide using J 42899 valve guide installer...

Page 751: ...d 2 Crankcase with Oil Pan 3 Oil Pipe 4 Oil Strainer 5 Oil Gallery 6 Piston with Connecting Rod Assembly 1 Remove cylinder head assembly D Refer to removal procedure for Cylinder Head in this manual 2...

Page 752: ...must be the same as connecting rod number D Apply engine oil to the thread and seating surface of each nut D Tighten nuts to the specified torque Torque 54 N m 40 lb ft D After tightening the nuts mak...

Page 753: ...Flywheel 12 Rear Oil Seal Retainer 13 Connecting Rod Cap 14 Crankshaft Main Bearing Cap 15 Crankshaft and Main Bearing 1 Remove engine assembly D Refer to removal procedure for Engine Assembly in thi...

Page 754: ...asher on No 3 journal D Oil grooves in thrust washer must face the crankshaft 015RS012 015RS013 2 Install crankshaft main bearing caps D Apply engine oil to the thread and seating surface of each bear...

Page 755: ...and flywheel fitting surface NOTE D Do not reuse the bolts D Do not apply oil or thread lock to the bolts D Tighten fixing bolts to the specified torque Torque 54 N m 40 lb ft 015RS018 6 Install oil g...

Page 756: ...torque Torque 25 N m 18 lb ft 11 Install crankcase D Remove oil on crankcase mounting surface and dry the surface D Properly apply a 4 5 mm 0 7 in wide bead of sealant TB1207C or equivalent to the cr...

Page 757: ...lts to the specified torque Torque 25 N m 18 lb ft 013RW003 013RW002 13 Install timing belt D Refer to installation procedure for Timing Belt in this manual 14 Install engine assembly D Refer to insta...

Page 758: ...tapped holes in the crankshaft D Remove oil on the crankshaft and flywheel mounting surface D Tighten fixing bolts to the specified torque NOTE Do not reuse the bolts and do not apply oil or thread l...

Page 759: ...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 fa...

Page 760: ...ansmission 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...

Page 761: ...e terminal on left bank 18 Reconnect bonding cable terminal on the back of right dash panel 19 Reconnect ground cable between engine and chassis 20 Reconnect harness connector to transmission and inst...

Page 762: ...inder Head Bolt 3 Camshaft Drive Gear Pulley Fixing Bolt 4 Camshaft Drive Gear Pulley 5 Camshaft Bearing Cap Fixing Bolt 6 Camshaft Bearing Cap 7 Camshaft Exhaust 8 Camshaft Intake 9 Retainer Fixing B...

Page 763: ...sh on any gasket sealing surface Inspection and Repair 1 Cylinder head gasket and mating surfaces for leaks corrosion and blow by If the gasket has failed determine the cause Insufficient torque on he...

Page 764: ...bly and camshaft bearing cap tighten twenty bolts on one side bank to the specified torque 1 Apply engine oil to camshaft journal and bearing surface of camshaft bearing cap 2 Align timing mark on int...

Page 765: ...t Drive Gear 4 Alignment Mark on Camshaft 5 Alignment Mark on Retainer 3 Tighten twenty bolts in numerical order on one side bank as shown in the illustration Torque 10 N m 89 lb in 014RW031 5 Tighten...

Page 766: ...earing Cap Fixing Bolts 2 Camshaft Assembly Inlet 3 Camshaft Assembly Exhaust 4 Shim 5 Tappet 6 Split Collar 7 Spring Upper Seat 8 Valve Spring 9 Oil Controller 10 Spring Lower Seat 11 Valve Guide 12...

Page 767: ...in Limit 43 6 mm 1 7165 in 014RS004 2 Measure the valve spring squareness with a steel square and replace the valve springs if the measured value exceeds the specified limit Limit 2 mm 0 0787 in 014RS...

Page 768: ...787 in Exhaust clearance Standard 0 030 mm 0 063 mm 0 0012 in 0 0025 in Limit 0 20 mm 0 00787 in Valve Guide Replacement 1 Using Valve guide replacer J 42899 drive out the valve guide from the combust...

Page 769: ...he limit replace valve valve guide and valve seat as a set Valve contact surface angle 45 014RS012 Valve Seat Insert Correction 1 Remove the carbon from the valve seat insert surface 2 Use a valve cut...

Page 770: ...orizontally Standard fitting interference 0 14 mm 0 09 mm 0 0055 in 0 0035 in 7 After insertion use a seat grinder to grind finish the seating face Carefully note the seating angle the contact width a...

Page 771: ...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...

Page 772: ...L 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 014R...

Page 773: ...olt 2 Camshaft Bearing Cap 3 Camshaft Assembly Intake 4 Camshaft Assembly Exhaust 5 Pulley Fixing Bolt 6 Camshaft Drive Gear Pulley 7 Retainer Fixing Bolt 8 Retainer 9 Camshaft Drive Gear 10 Oil Seal...

Page 774: ...he uneven wear exceeds the specified limit Lobe height 44 709 mm 1 7602 in Uneven wear 0 05 mm 0 0020 in 014RW043 2 Use a micrometer to measure the diameter and the uneven wear of the camshaft journal...

Page 775: ...0 11 mm 0 0043 in 014RW037 5 Replace the cylinder head and or camshaft if the measured oil clearance exceeds the specified limit 1 Carefully clean the camshaft journal the camshaft bracket and the cy...

Page 776: ...o the specified torque 1 Apply engine oil to camshaft journal and bearing surface of camshaft bearing cap 2 Align timing mark on intake camshaft one dot for right bank two dots for left bank and exhau...

Page 777: ...Camshaft Drive Gear 4 Alignment Mark on Camshaft 5 Alignment Mark on Retainer 3 Tighten twenty bolts in numerical order on one side bank as shown in the illustration Torque 10 N m 89 lb in 014RW031 4...

Page 778: ...6A 65 ENGINE MECHANICAL 5 Tighten bolt for camshaft drive gear pulley to the specified torque using the J 43041 universal holder Torque 98 N m 72 lb ft 014RW060...

Page 779: ...ankcase with Oil Pan 3 Oil Pipe and O Ring 4 Oil Strainer and O Ring 5 Oil Pump Assembly 6 Cylinder Block Side Bolts 7 Oil Gallery 8 Piston and Connecting Rod Assembly 9 Flywheel 10 Rear Oil Seal Reta...

Page 780: ...s the specified limit replace the thrust bearings as a set Thrust Clearance Standard 0 06 mm 0 24 mm 0 0024 in 0 0094 in Limit 0 30 mm 0 0118 in 015RS003 Main Bearing Clearance 1 Remove the bearing ca...

Page 781: ...rance If the oil clearance exceeds the specified limit replace the main bearings as a set and or replace the crankshaft Standard 0 019 mm 0 043 mm 0 0007 in 0 0017 in Limit 0 08 mm 0 0031 in 015RS008...

Page 782: ...stalling 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 Dia...

Page 783: ...0 63 926 63 933 2 5168 2 5170 1 Yellow Yellow 0 026 0 045 0 0010 0 0018 Reassembly 1 Crankshaft 12 D Install the main bearings to the cylinder block and the main bearing caps D Be sure that they are p...

Page 784: ...retainer 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 015RW001 015RS017 3 Flywheel 9 1 Thorough...

Page 785: ...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...

Page 786: ...urfaces 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 a...

Page 787: ...onnecting Rod 12 Connecting Rod Cap Disassembly 1 Remove cylinder head assembly 1 Refer to Cylinder Head Removal in this manual 2 Remove cylinder head gasket 2 3 Remove crankcase with oil pan 3 Refer...

Page 788: ...moval of the piston pin 015RS023 Legend 1 Press Ram 2 Piston 3 Connecting Rod 4 Piston Pin 11 Piston 10 12 Connecting rod 11 Inspection and Repair Pistons 10 Carefully clean away all the carbon adheri...

Page 789: ...12RS002 Piston Rings 8 Any worn or damaged part discovered during engine overhaul must be replaced with a new one 1 Ring end gap measurement D Insert the piston ring into the bore D Push the ring by t...

Page 790: ...ston must be replaced Compression Ring Clearance Standard 0 016 mm 0 038 mm 0 0006 in 0 0015 in Limit 0 15mm 0 0059 in 015RS028 Piston Pin 9 NOTE Do not reuse the old piston pin 1 Use a micrometer to...

Page 791: ...gauge to measure the thrust clearance at the large end of the connecting rod If the clearance exceeds the specified limit the connecting rod must be replaced Standard 0 16 mm 0 35 mm 0 0063 in 0 0138...

Page 792: ...Connecting Rod Bearing Thickness Reference Color of Size Mark Oil Clearance Reference A 56 994 57 000 2 2439 2 2441 1 512 1 516 0 0595 0 0597 Yellow 0 025 0 054 0 0010 0 0021 B 56 988 56 994 2 2436 2...

Page 793: ...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...

Page 794: ...8 Oil Gallery 9 Piston and Connecting Rod Assembly 10 Flywheel 11 Rear Oil Seal Retainer Assembly 12 Main Bearing Cap 13 Crankshaft 14 Cylinder Block Disassembly 1 Remove cylinder head assembly 2 Rem...

Page 795: ...ul 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 regro...

Page 796: ...bearing upper and lower 2 Number 2 and 3 main bearing upper 3 Number 2 and 3 main bearing lower D Carefully mount the crankshaft D Apply engine oil to the thrust washer D Assemble the thrust washer to...

Page 797: ...bolts in the order shown Torque 54 N m 40 lb ft NOTE Do not reuse the bolts and do not apply oil or thread lock to the bolts 015RS018 5 Install piston and connecting rod assembly D Apply engine oil t...

Page 798: ...il 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 t...

Page 799: ...rive 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...

Page 800: ...6A 87 ENGINE MECHANICAL Torque Specifications Ignition coil Spark plug Crankshaft position sensor and Under cover E06RY001...

Page 801: ...6A 88 ENGINE MECHANICAL Cylinder head cover Cylinder head Camshaft bearing cap Common chamber EGR valve and EGR pipe Ion sensing module E06RY00001...

Page 802: ...6A 89 ENGINE MECHANICAL 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...

Page 803: ...6A 90 ENGINE MECHANICAL Connecting rod and Water pump E06RW011...

Page 804: ...6A 91 ENGINE MECHANICAL Engine mount E06RW003...

Page 805: ...J 42898 Adapter Compressor Valve spring 2 J 37281 Remover Oil controller J 38537 Installer Oil controller J 29107 Universal pitman arm puller ILLUSTRATION TOOL NO TOOL NAME J 42985 Installer Camshaft...

Page 806: ...OL NO 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 Leve...

Page 807: ...AR 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...

Page 808: ...dy 10 Cylinder Block 11 Cylinder Head 12 Left Bank 13 Heater The cooling system is a pressurized Engine Coolant EC forced circulation type which consists of a water pump thermostat cooling fan radiato...

Page 809: ...T 110RS001 Anti Freeze Solution D Relation between the mixing ratio and freezing temperature of the EC varies with the ratio of anti freeze solution in water Proper mixing ratio can be determined by r...

Page 810: ...ifreeze 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...

Page 811: ...Clogged radiator Clean or replace Faulty radiator cap Replace Low engine oil level or use of improper engine oil Replenish or change oil Clogged exhaust system Clean exhaust system or replace faulty p...

Page 812: ...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 pe...

Page 813: ...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 a...

Page 814: ...ntainer using thin wire Place a thermometer next to the thermostat Do not directly heat the thermostat Gradually increase the water temperature Stir the water so that the entire water is same temperat...

Page 815: ...Bracket 6 Radiator Assembly 7 Reserve Tank Removal 1 Disconnect battery ground cable 2 Loosen a drain plug 2 to drain EC 3 Disconnect oil cooler hose 1 on automatic transmission A T 4 Disconnect radia...

Page 816: ...t or dirt is found or if the valve seat cannot be moved by hand clean or replace the cap Valve opening vacuum kPa psi 1 96 4 91 0 28 0 71 110RS006 Radiator Core 1 A bent fin may result in reduced vent...

Page 817: ...TEMPERATURE BE SURE NOT TO LOOSEN OR REMOVE THE RADIATOR CAP OTHERWISE YOU MIGHT GET SCALDED BY HOT VAPOR OR BOILING WATER TO OPEN THE RADIATOR CAP PUT A PIECE OF THICK CLOTH ON THE CAP AND LOOSEN THE...

Page 818: ...cooling fan assembly and tighten bolts nuts to the specified torque 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 NOTE Fan belts for 6VE1...

Page 819: ...t 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...

Page 820: ...6B 14 ENGINE COOLING Special Tool ILLUSTRATION TOOL NO TOOL NAME J 24460 01 Tester radiator cap J 33984 A Adapter radiator cap...

Page 821: ...TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SR...

Page 822: ...ing on the fuel system there are several things to keep in mind D Any time the fuel system is being worked on disconnect the negative battery cable except for those tests where battery voltage is requ...

Page 823: ...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 E...

Page 824: ...move Fuel filler cap 1 3 Disconnect fuel hoses 2 from fuel filter on both engine side and fuel tank side 4 Fuel filter fixing bolt 3 D Remove the fuel filter fixing bolt 3 on fuel filter holder 5 Remo...

Page 825: ...ned 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 a...

Page 826: ...uel 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 f...

Page 827: ...er Hose and Evapo Hose 3 Undercover 4 Fuel Tank Wiring Connector 5 Evapo Fuel Hose 6 Fuel Feed Tube and Fuel Return Tube Quick Connect Fittings 7 Fuel Tank Removal CAUTION When repair to the fuel syst...

Page 828: ...nnect 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...

Page 829: ...hand while pressing the square relieve button of the retainer as illustrated 141RW020 NOTE This work should be done by hands Do not use any tools Should the pipe can hardly be removed from the connec...

Page 830: ...ust 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 t...

Page 831: ...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 Wiring connector D Disconnect wiring connector 1 from the...

Page 832: ...lve 2 Pressure Valve 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...

Page 833: ...ery 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 discha...

Page 834: ...LISTED IN THE TABLE The battery is good and should be returned to service b VOLTAGE IS LESS THAN MINIMUM LISTED Replace battery ESTIMATED TEMPERATURE MINIMUM VOLTAGE F C V 70 21 9 6 60 16 9 5 50 10 9...

Page 835: ...tion Turn OFF the ignition Turn OFF all lights and any other accessory requiring electrical power 2 Look at the built in hydrometer If the indication area of the built in hydrometer is completely clea...

Page 836: ...ns General Specifications 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 Ma...

Page 837: ...G REFER TO THE SRS SERVICE INFORMATION FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT PERSONAL INJURY OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS CAUTION Always use the correct fa...

Page 838: ...dule position angle sensor powertrain control module PCM and other components The ignition coils are connected with the PCM by means of a 80 pin connector The ignition control module turns on off the...

Page 839: ...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...

Page 840: ...nt 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 Sh...

Page 841: ...k plug reduces the engine performance Possible causes D Too rich mixture D Presence of oil in combustion chamber D Incorrectly adjusted spark plug gap Burning Electrodes This fault is characterized by...

Page 842: ...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 am...

Page 843: ...ral Specifications 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 i...

Page 844: ...VICE 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 COU...

Page 845: ...aft 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 lev...

Page 846: ...6D3 3 STARTING AND CHARGING SYSTEM C06RY00002...

Page 847: ...n 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 fai...

Page 848: ...rd the bottom of engine 6 065RW027 Installation 1 Install starter assembly 6 2 Install mounting bolts and tighten bolts to specified torque 5 Torque 40 N m 30 lb ft 3 Reconnect the connectors to termi...

Page 849: ...over 6 Torsion Spring 7 Dust Cover 8 Magnetic Switch 9 Nut 10 Gear Case 11 Bearing Cover 12 E Ring 13 Thrust Washer 2 14 Center Bracket 15 Pinion Shaft 16 Planet Gear 3 17 Internal Gear 18 Center Brac...

Page 850: ...torsion spring bolts then the magnetic switch assembly 6 Remove torsion spring 3 from magnetic switch assembly 5 065RW004 7 Remove screw 2 pcs 8 8 Remove through bolt 2 pcs 7 9 Remove screws and thro...

Page 851: ...re and pull off slowly the yoke assembly Because of strong magnetic force avoid placing a metallic part near armature 065RW007 15 Remove dust cover 17 16 Remove a dust cover and shift lever 16 from th...

Page 852: ...nion 24 Remove thrust washer 24 25 Remove center bracket 26 Remove pinion shaft 065RW011 Inspection and Repair Repair or replace necessary parts if extreme wear or damage is found during inspection Ar...

Page 853: ...utator with a dial gauge Repair or replace if it exceeds the limit Armature Standard 0 05 mm 0 002 in Max Limit 0 10 mm 0 004 in Commutator Standard 0 05 mm 0 002 in Max Limit 0 10 mm 0 004 in 065RS01...

Page 854: ...continuity between brush holder 4 and base Replace if there is continuity i e insulation is broken 065RW015 Magnetic Switch Check for continuity of shunt coil between terminals S and M Replace if ther...

Page 855: ...lty 065RW018 Pinion Check if the pinion rotates smoothly in drive direction by hand or if it is locked when it is rotated in reverse If not replace the pinion 065RS025 Yoke Assembly Check a magnet ins...

Page 856: ...r 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...

Page 857: ...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...

Page 858: ...umber 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 Volt...

Page 859: ...6D3 16 STARTING AND CHARGING SYSTEM Torque Specifications E06RW023...

Page 860: ...6D3 17 STARTING AND CHARGING SYSTEM E06RW024...

Page 861: ...of generator General On Vehicle Inspection The operating condition of charging system is indicated by the charge warning lamp The warning lamp comes on when the starter switch is turned to ON position...

Page 862: ...uires 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 o...

Page 863: ...GING SYSTEM Disassembled View 066RW007 Legend 1 Pulley Nut 2 Pulley 3 Front Cover Assembly 4 Rotor Assembly 5 Rear End Cover 6 Rectifier 7 Terminal Insulator and Nut 8 Regulator Assembly 9 Brush Holde...

Page 864: ...terminal B and insulator then remove the rear cover 3 060RW005 3 Remove two screws that fix the brush holder 5 and rectifier then remove the brush holder assembly 4 060RW004 4 Remove three screws on...

Page 865: ...remove the nut and pulley 066RS010 7 Remove four nuts 8 that secure the front cover assembly and rear end cover and an insulator 9 066RW005 8 Use the puller to remove the rear end cover 9 Rotor assem...

Page 866: ...slip ring surfaces for contamination and roughness If rough polish with 500 600 sandpaper 066RS014 2 Measure the slip ring diameter and replace if it exceeds the limit 066RS015 3 Check resistance bet...

Page 867: ...ectifier Assembly Check for continuity across P and E in the 100W range of multimeter 066RW002 Change polarity and make sure that there is continuity in one direction and not in the reverse direction...

Page 868: ...wo copper plates and tighten nut to the specified torque Torque 111 N m 82 lb ft 066RS010 Bench Test Conduct a bench test of the generator 066RS023 Preparation Remove generator from the vehicle see Ge...

Page 869: ...and Specifications General Specifications 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 d...

Page 870: ...38 OBD II Serviceablity Issues 6E 38 Emissions Control Information Label 6E 38 Visual Physical Engine Compartment Inspection 6E 38 Basic Knowledge of Tools Required 6E 39 Serial Data Communications 6...

Page 871: ...n 6E 97 Engine Cranks But Will Not Run 6E 99 Circuit Description 6E 101 Diagnostic Aids 6E 101 Test Description 6E 101 Fuel System Electrical Test 6E 106 Circuit Description 6E 107 Diagnostic Aids 6E...

Page 872: ...292 P0352 Ignition 2 Control Circuit 6E 295 P0353 Ignition 3 Control Circuit 6E 298 P0354 Ignition 4 Control Circuit 6E 301 P0355 Ignition 5 Control Circuit 6E 304 P0356 Ignition 6 Control Circuit 6E...

Page 873: ...xygen Sensor HO2S 6E 528 Intake Air Temperature IAT Sensor 6E 531 ION Sensing Module 6E 531 Mass Air Flow MAF Sensor 6E 532 Manifold Absolute Pressure MAP Sensor 6E 533 Malfunction Indicator Lamp MIL...

Page 874: ...ering System Purpose 6E 570 Fuel Pressure Regulator 6E 570 Fuel Pump Electrical Circuit 6E 570 Fuel Rail 6E 570 Run Mode 6E 571 Starting Mode 6E 571 Throttle Body Unit 6E 571 General Description Elect...

Page 875: ...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 4...

Page 876: ...6E 7 TROOPER 6VE1 3 5L ENGINE DRIVEABILITY AND EMISSIONS Diagrams and Schematics PCM Wiring Diagram 1 of 7 D06RY00156...

Page 877: ...6E 8 TROOPER 6VE1 3 5L ENGINE DRIVEABILITY AND EMISSIONS PCM Wiring Diagram 2 of 7 D06RY00150...

Page 878: ...6E 9 TROOPER 6VE1 3 5L ENGINE DRIVEABILITY AND EMISSIONS PCM Wiring Diagram 3 of 7 D06RY00042...

Page 879: ...6E 10 TROOPER 6VE1 3 5L ENGINE DRIVEABILITY AND EMISSIONS PCM Wiring Diagram 4 of 7 D06RY00044...

Page 880: ...6E 11 TROOPER 6VE1 3 5L ENGINE DRIVEABILITY AND EMISSIONS PCM Wiring Diagram 5 of 7 D06RY00149...

Page 881: ...6E 12 TROOPER 6VE1 3 5L ENGINE DRIVEABILITY AND EMISSIONS PCM Wiring Diagram 6 of 7 D06RY00115...

Page 882: ...6E 13 TROOPER 6VE1 3 5L ENGINE DRIVEABILITY AND EMISSIONS PCM Wiring Diagram 7 of 7 D06RY00127...

Page 883: ...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 F8 Not...

Page 884: ...6E 15 TROOPER 6VE1 3 5L ENGINE DRIVEABILITY AND EMISSIONS PIN Refer To ENG RUN IGN ON Wire Color PIN Function F19 Ignition Feed RED GRN B B 6D Section F20 Ignition Feed RED WHT B B 6D Section...

Page 885: ...e F26 ION Sensing Module RED BLK 1 555V 1 555V General Description and Operation ION Sensing Module F27 Intake Air Temperature IAT Sensor YEL GRN 0 5 4 9V 0 5 4 9V General Description and Operation IA...

Page 886: ...TROOPER 6VE1 3 5L ENGINE DRIVEABILITY AND EMISSIONS PIN Refer To ENG RUN IGN ON Wire Color PIN Function F39 Brake Swich GRN YEL 0 0V 0 0V 4L30E T Mission F40 PCM Ground BLK RED 0 0V 0 0V Chassis Elect...

Page 887: ...aptor Case VIO RED B B 4L30E T Mission F48 Throttle Valve DC Motor BLK Duty Cycle Duty Cycle General Description and Operation ETC F49 Shielded Wire ION Sensing Module SIL 0 0V 0 0V Chassis Electrical...

Page 888: ...6E 19 TROOPER 6VE1 3 5L ENGINE DRIVEABILITY AND EMISSIONS PIN Refer To ENG RUN IGN ON Wire Color PIN Function F59 Not Used F60 Shielded Wire SIL 0 0V 0 0V Chassis Electrical...

Page 889: ...nder 3 GRN B B General Description and Operation Fuel Injector 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 Ge...

Page 890: ...Refer To ENG RUN IGN ON Wire Color PIN Function 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 Sens...

Page 891: ...0V 0 0V Chassis Electrical S7 Fuel Gauge YEL RED B B Chassis Electrical S8 Not Used S9 Not Used S10 Shift High Band Apply BRN YEL B B 4L30E T Mission S11 Malfunction Indicator Check Engine Lamp VIO 0...

Page 892: ...ire Color PIN Function S18 Bank 1 HO2S 1 Low GRN 0 0V 0 1V General Description and Operation Catalyst Monitor HO2S S19 ION Sensing Module RED YEL 1 555V 1 555V General Description and Operation ION Se...

Page 893: ...ctrical 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 Electric...

Page 894: ...OOPER 6VE1 3 5L ENGINE DRIVEABILITY AND EMISSIONS PIN Refer To ENG RUN IGN ON Wire Color PIN Function S39 Auto Cruise Lamp BLK ORN 0 0V 0 0V Chassis Electrical S40 PCM Ground BLK 0 0V 0 0V Chassis Ele...

Page 895: ...tem S46 A T Check Transmission Lamp ORN BLK B B Chassis Electrical 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...

Page 896: ...GN ON Wire Color PIN Function S58 Bank 2 HO2S 1 High RED 0 3V 0 1 0 9V General Description and Operation Catalyst Monitor HO2S S59 Auto Cruise Steering Set Switch Light GRN 0 0V 0 0V Chassis Electrica...

Page 897: ...Transmission Fluid Temperature Sensor RED WHT 0 5 4 9V depends on temperature 0 5 4 9V depends on temperature 4L30E T Mission S67 Exhaust Gas Recirculation EGR YEL RED 0 6V 0 6V General Description an...

Page 898: ...0V 5 0V Appropriate Sensor S78 Accelerate Position AP Sensor 2 YEL 0 41 0 45V 0 41 0 45V General Description and Operation AP Sensor S79 Accelerate Position AP Sensor 3 BLU GRN 4 55 4 99V 0 41 0 45V G...

Page 899: ...6E 30 TROOPER 6VE1 3 5L ENGINE DRIVEABILITY AND EMISSIONS Component Locators Engine Component Locator 060RY00070...

Page 900: ...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...

Page 901: ...er 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 t...

Page 902: ...6E 33 TROOPER 6VE1 3 5L ENGINE DRIVEABILITY AND EMISSIONS Fuse and Relay Panel Underhood Electrical Center 065RY00003...

Page 903: ...6E 34 TROOPER 6VE1 3 5L ENGINE DRIVEABILITY AND EMISSIONS Sensors and Miscellaneous Component Locators 060RY00013 T321067 T321068 060RX00005 060RW111 141RY00001...

Page 904: ...6E 35 TROOPER 6VE1 3 5L ENGINE DRIVEABILITY AND EMISSIONS 055RY00002 041RW004 025RW005 T321078 060RY00014 060RY00016...

Page 905: ...6E 36 TROOPER 6VE1 3 5L ENGINE DRIVEABILITY AND EMISSIONS 060RY00023...

Page 906: ...other method to identify the circuit or electrical system component 4 Follow the suggestions for intermittent diagnosis found in the service documentation Most Scan Tools such as the Tech 2 have data...

Page 907: ...ine misfire and turn on the MIL Check Engine lamp Refueling A new OBD II diagnostic was introduced in 1996 on some vehicles This diagnostic checks the integrity of the entire evaporative emission syst...

Page 908: ...ds the following data D The diagnostic test has been completed since the last ignition cycle D The diagnostic test has passed during the current ignition cycle D The fault identified by the diagnostic...

Page 909: ...t to determine if the system or component is operating according to specification There are many diagnostics shown in the following list D Misfire D Oxygen sensors D Oxygen sensor heaters D EGR D Cata...

Page 910: ...will remain in the PCM memory both Freeze Frame and Failure Records until forty 40 warm up cycles after no faults have been completed If the MIL was set by either a fuel trim or misfire related DTC ad...

Page 911: ...the engine load conditions are within 10 of the previous test that failed D Engine speed is within 375 rpm of the previous test that failed D Engine coolant temperature is in the same range as the pre...

Page 912: ...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...

Page 913: ...ND EMISSIONS Tech 2 From 98 MY Isuzu dealer service departments are recommended to use the Tech 2 Scan Tool Please refer to the Tech 2 user guide 901RW180 Legend 1 PCMCIA Card 2 RS 232 Loop Back Conne...

Page 914: ...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...

Page 915: ...L ENGINE DRIVEABILITY AND EMISSIONS 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 belo...

Page 916: ...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 pr...

Page 917: ...of electric circuits To judge intermittent trouble 1 Confirm DTC freeze frame data and match the freeze frame data as test conditions with the data list displayed by Miscellaneous Test 2 Confirm DTC...

Page 918: ...amp 060RY00092 14 Push On of soft key 15 Make sure Lamp illuminates 16 If Lamp illuminates the Lamp is operating correctly 17 Select F3 Reduced Power Lamp 060RY00077 18 Push On of soft key 19 Make sur...

Page 919: ...Connect Tech 2 to the vehicle DLC 2 Ignition SW is On 3 Select F3 Miscellaneous Test in the Application Menu 060RY00075 4 Select F1 Relay Test in the Miscellaneous Test 060RY00081 5 Select F0 Fuel Pum...

Page 920: ...st changes the Fuel Pump Relay is normal EVAP Test This test is conducted to check EVAP system for its power operation Tech 2 must be used for this test Test Procedure 1 Connect Tech 2 to the vehicle...

Page 921: ...SW On 10 Select F1 EVAP Vent Solenoid 060RX025 11 Push On or Off soft key 060RY00096 12 Control EVAP Vent Solenoid and check data list 13 If the data list changes the EVAP Vent Solenoid is normal Fuel...

Page 922: ...t F3 Fuel System in the Miscellaneous Menu 060RY00083 5 Select F0 Fuel Trim Enable 060RY00079 6 Push Disable or Enable soft key 060RY00097 7 Control Fuel Trim and check data list 8 If data list change...

Page 923: ...e 13 Push Open Loop or Closed Loop soft key 060RY00099 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 fo...

Page 924: ...n the Miscellaneous Menu 060RY00106 5 Select F0 Fuel Gauge level 060RY00107 6 Push Decrease or Increase soft key 060RY00100 7 Control Fuel Level and check data list 8 If data list and Fuel gauge meter...

Page 925: ...or 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 060RY00075 4 Select F5 EGR Control Test in the Miscellan...

Page 926: ...is On 060RY00104 3 Select F3 Miscellaneous Test in the Application Menu 060RY00075 4 Select F6 Variable Intake Manifold Solenoid Test 060RY00085 5 Push On or Off of soft key 060RX028 6 Control VIM Sol...

Page 927: ...jector off soft key 060RY00105 6 Make sure of engine speed change 7 If engine speed changes the injector electric circuit is normal If engine speed does not change the injector electric circuit or the...

Page 928: ...6E 59 TROOPER 6VE1 3 5L ENGINE DRIVEABILITY AND EMISSIONS Plotting Graph Flow Chart Plotting graph after obtaining vehicle information D06RY00167...

Page 929: ...6E 60 TROOPER 6VE1 3 5L ENGINE DRIVEABILITY AND EMISSIONS Flow Chart for Snapshot Replay Plotting Graph 060RX040...

Page 930: ...xygen present in the exhaust gases The control module uses the signal voltage from the fuel control heated oxygen sensors while in closed loop to adjust fuel injector pulse width While in closed loop...

Page 931: ...urer sensor This may lead to a false pass or a false fail of the catalyst monitor diagnostic Similarly if an aftermarket catalyst does not contain the same amount of cerium as the original part the co...

Page 932: ...rim 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...

Page 933: ...f not the No MIL chart should be used to isolate the malfunction 2 The RPL Reduced Power lamp should be ON steady with the ignition ON engine OFF If not the No RPL chart should be used to isolate the...

Page 934: ...Go to MIL Check Engine lamp On Steady 5 1 Using the Tech 2 output tests function select MIL Reduced Power lamp control and command the MIL Reduced Power lamp OFF 2 Observe the MIL Reduced Power lampp...

Page 935: ...it 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 Re...

Page 936: ...ge whenever A C has been selected with the engine running unless any of the following conditions are present D The throttle is greater than 90 D The ignition voltage is below 10 5 volts D The engine s...

Page 937: ...t the same time so the substitution process is one way to check the A C Thermostat relay Use a known good relay to do a substitution check A C Clutch Control Circuit Diagnosis Step Action Value s Yes...

Page 938: ...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...

Page 939: ...then Down Load the LATEST PROGRAMMED SOFTWARE to the replacement PCM Is the action complete Verify repair 26 1 Remove the A C compressor relay 2 Ignition ON 3 Use a DVM to check voltage at both of th...

Page 940: ...tch or replace the compressor due to a faulty internal overheat switch Is the action complete Verify repair 37 1 Remove the A C compressor relay 2 Idle the engine Is the compressor clutch still engage...

Page 941: ...the long term fuel trim values which can be monitored with a Tech 2 Ideal long term fuel trim values are around 0 for a lean HO2S signal the PCM will add fuel resulting in a fuel trim value above 0 S...

Page 942: ...is necessary in order to avoid irregular fuel pressure readings due to Hot Soak fuel boiling Injector Coil Test Procedure Steps 1 6 and Injector Balance Test Procedure Steps 7 11 R262001 CYLINDER 1 2...

Page 943: ...r 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 t...

Page 944: ...tage 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...

Page 945: ...uel 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...

Page 946: ...ating conditions The PCM controls fuel delivery spark advance transmission operation and emission control device operation based on the sensor inputs The PCM provides a sensor ground to all of the sen...

Page 947: ...t 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 wi...

Page 948: ...poor connection Go to Step 5 Go to Step 6 5 Repair the open or the poor connection Is the action complete Verify repair 6 Following below the DTCs stored P1635 P1639 P1646 Go to applicable DTC table G...

Page 949: ...nect the CKP and CMP sensor connector 2 Ignition ON 3 Measure the voltage below the items D CKP sensor GND circuit and shield circuit D CMP sensor GND circuit and shield circuit Does the voltage resis...

Page 950: ...s commanding The PCM will compensate for various engine loads based on engine coolant temperature to keep the engine at the desired speed ECT Engine Coolant Temperature Tech 2 Range 40 C to 151 C 40 F...

Page 951: ...N 2 Tech 2 Range 00 00 00 99 99 99 HRS MIN SEC Indicates warm up time for each HO2S The HO2S warm up time is used for the HO2S heater test The PCM will run the heater test only after a cold start dete...

Page 952: ...cates the engine coolant temperature at the time that the vehicle was started Used by the HO2S diagnostic to determine if the last start up was a cold start START UP IAT Tech 2 Range 40 C to 151 C 40...

Page 953: ...V Open 0V Refer to Section 5 Check Trans Lamp Auto Trans Engine On Off Off Off 4L30 E Automatic Transmission Diagnosis Cruise Main Switch Engine Active Inac tive Inactive Inactive Refer to Section 10...

Page 954: ...02 1 86 1 02 2 57 General Description and Operation Pressure Sensor in H2O O eration Fuel Pump Engine On Off On On Engine Fuel HO2S Bank 1 Sen 1 millivolts O2 Sensor Data Millivolts 50 950 changing qu...

Page 955: ...depends on underhood General Description and Operation Intake Air Temperature IAT Sensor Illumination Switch Engine Closed 0V Open 12V Closed 0V Closed 0V Refer to Section 8 Ignition Voltage Engine V...

Page 956: ...l 2 Misfire Counts 0 0 DTC P0300 Misfire Hist Cyl 3 Misfire Counts 0 0 DTC P0300 Misfire Hist Cyl 4 Misfire Counts 0 0 DTC P0300 Misfire Hist Cyl 5 Misfire Counts 0 0 DTC P0300 Misfire Hist Cyl 6 Misf...

Page 957: ...tive Active Active Refer to Section 10 Total Misfire Current Count Misfire Counts 0 5 0 5 DTC P0300 TP Sensor 1 Throttle Position Sensor 1 Engine Percent 3 13 12 21 General Description and Operation...

Page 958: ...in the instrument cluster ignition feed D If the engine cranks but will not run check for an open PCM ignition or battery feed or a poor PCM to engine ground Test Description Number s below refer to t...

Page 959: ...and 15 A PCM fuse Are both fuses OK Go to Step 7 Go to Step 15 7 1 Ignition OFF 2 Disconnect the PCM 3 Ignition ON 4 Probe the ignition feed circuit at the PCM harness connector with a test light to...

Page 960: ...ster and replace the fuse Is the action complete Verify repair 17 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to PCM in ON Vehicle Service for procedures And also refer to l...

Page 961: ...ection 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 mati...

Page 962: ...Check Go to Step 4 4 Replace the instrument panel cluster Is the action complete Go to OBD System Check 5 1 Ignition OFF reconnect the PCM 2 Ignition ON reprogram the EEPROM Refer to On Vehicle Servic...

Page 963: ...he instrument cluster ignition feed D If the engine cranks but will not run check for an open PCM ignition or battery feed or a poor PCM to engine ground Test Description Number s below refer to the s...

Page 964: ...15 A PCM fuse Are both fuses OK Go to Step 7 Go to Step 15 7 1 Ignition OFF 2 Disconnect the PCM 3 Ignition ON 4 Probe the ignition feed circuit at the PCM harness connector with a test light to grou...

Page 965: ...hefuse Is the action complete Verify repair 17 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...

Page 966: ...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 bro...

Page 967: ...ck Go to Step 4 4 Replace the instrument panel cluster Is the action complete Go to OBD System Check 5 1 Ignition OFF reconnect the PCM 2 Ignition ON reprogram the EEPROM Refer to On Vehicle Service i...

Page 968: ...6E 99 TROOPER 6VE1 3 5L ENGINE DRIVEABILITY AND EMISSIONS Engine Cranks But Will Not Run D06RY00150...

Page 969: ...6E 100 TROOPER 6VE1 3 5L ENGINE DRIVEABILITY AND EMISSIONS D06RY00042...

Page 970: ...ture 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 Test Description Number s below re...

Page 971: ...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...

Page 972: ...uel filter and replace any injectors that are not delivering fuel see Injector Balance Test Was a problem found Verify repair Go to Step 19 19 1 Remove any ignition coil and install a spark tester at...

Page 973: ...in connector Is the test light ON Go to Step 26 Go to Step 32 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...

Page 974: ...software is released or not And then Down Load the LATEST PROGRMMED SOFTWARE to the replacement PCM Is the action complete Verify repair 34 1 Raise the vehicle and disconnect the CKP sensor harness 2...

Page 975: ...6E 106 TROOPER 6VE1 3 5L ENGINE DRIVEABILITY AND EMISSIONS Fuel System Electrical Test D06RY00150...

Page 976: ...t the PCM harness and connectors for improper mating broken locks improperly formed or damaged terminals poor terminal to wire connection and damaged harness Test Description Number s below refer to t...

Page 977: ...obe the battery feed to the relay Did the light illuminate Go to Step 6 Go to Step 5 5 Repair short or open battery feed to fuel pump relay Is the action complete Verify repair 6 1 Connect a test ligh...

Page 978: ...t 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 illumin...

Page 979: ...6E 110 TROOPER 6VE1 3 5L ENGINE DRIVEABILITY AND EMISSIONS Electric Throttle Control ETC System Check D06RY00179...

Page 980: ...ation 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 termina...

Page 981: ...ration pedal Did any of the above require a repair Refer to appropriate section for on vehicle service Go to Step 3 3 Visually physically inspect for the following conditions D Acceleration pedal tamp...

Page 982: ...sition sensor 3 circuit D Acceleration position sensor resistance If a problem is found repair as necessary Was a problem found Vcc GND 4 6km SIG GND change resistance Verify repair Go to Step 9 9 Rep...

Page 983: ...p supplies fuel through an in line fuel filter to the fuel rail assembly The fuel pump is designed to provide fuel at a pressure above the pressure needed by the fuel injectors A fuel pressure regulat...

Page 984: ...are intact D Pressurize the fuel system by connecting a 10 amp fused jumper between B and the fuel pump relay connector D Visually and physically inspect the fuel injector nozzles for leaks 17 A rich...

Page 985: ...e ignition ON to build fuel pressure and observe the measurement on the gauge 2 Start the engine and observe the fuel pressure gauge Did the reading drop by the amount specified after the engine was s...

Page 986: ...prevent fuel from returning to the fuel tank 3 Run the fuel pump with the Tech 2 4 After pressure has built up remove power to the pump Does the fuel pressure indicated by the fuel pressure gauge rem...

Page 987: ...hose gradually apply pressure with the pliers to pinch the flexible fuel return hose closed CAUTION Do not let the fuel pressure exceed the second specified value Does the fuel pressure indicated by...

Page 988: ...would be replaced with air and the air fuel mixture would be leaner The powertrain control module PCM would compensate for the lean condition by adding fuel resulting in higher long term fuel trim val...

Page 989: ...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 restricti...

Page 990: ...rometric pressure allowing the PCM to make adjustments for different altitudes The PCM uses the MAP sensor to diagnose proper operation of the EGR system in addition to other functions Test Descriptio...

Page 991: ...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 vol...

Page 992: ...s enabled when the appropriate conditions have been met D The engine run time after start is more than 60 seconds D The engine coolant temperature is above 30 C 86 F D The fuel control system is opera...

Page 993: ...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...

Page 994: ...alve check Refer to Diagnostic 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 te...

Page 995: ...6E 126 TROOPER 6VE1 3 5L ENGINE DRIVEABILITY AND EMISSIONS Upshift Lamp System Check Manual Transmission Only 060RY00127...

Page 996: ...PCM 2 This checks the upshift lamp circuit up to the PCM connector If the up shift lamp illuminates then the PCM connector is faulty or PCM does not have the ability to ground the circuit Up Shift Lam...

Page 997: ...it Was a problem found Go to Step 11 Go to Step 12 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 connecto...

Page 998: ...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...

Page 999: ...nal 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 P035...

Page 1000: ...put 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 In...

Page 1001: ...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 Ope...

Page 1002: ...11 5 volts and 16 volts Action Taken When the DTC Sets D The PCM will illuminate the malfunction indicator lamp MIL the first time the fault is detected D The PCM calculates an air flow value based on...

Page 1003: ...hart may isolate the cause of the fault DTC P0101 MAF System Performance Step Action Value s Yes No 1 Was the On Board Diagnostic OBD System Check performed Go to Step 2 Go to OBD System Check 2 1 Ign...

Page 1004: ...ng 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...

Page 1005: ...mp MIL the first time the fault is detected D The PCM calculates an air flow value based on idle air control valve position throttle position RPM and barometric pressure D The PCM will store condition...

Page 1006: ...OFF 2 Review and record Tech 2 Failure Records data 3 Operate the vehicle within Failure Records conditions as noted 4 Using a Tech 2 monitor DTC info for DTC P0102 Does the Tech 2 indicate DTC P0102...

Page 1007: ...action complete Verify repair Go to Step 13 11 Locate and repair the open in the ground circuit to the MAF sensor Is the action complete Verify repair 12 Locate and repair the open in the ignition fe...

Page 1008: ...M for more than 10 seconds D System voltage is above 11 5 volts D MAF signal frequency is above 40g s for a total of 50 percent of the last 200 samples monitored A sample is taken every cylinder event...

Page 1009: ...4 A frequency reading with the MAF sensor connector disconnected indicates an electromagnetic interfernce EMI related fault 8 This vehicle is equipped with a PCM which utilizes an electrically erasab...

Page 1010: ...es the Tech 2 indicate a MAF Frequency at the specified value 0g s Go to Step 5 Go to Step 6 5 Replace the MAF sensor Is the action complete Verify repair Go to Step 8 6 1 Check the MAF harness for in...

Page 1011: ...han 4 D No change in brake switch A C clutch TCC or power steering pressure switch status D Above conditions are met for longer than 1 second D Actual MAP value varies more than 10 kPa D The MAP value...

Page 1012: ...tions 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 valv...

Page 1013: ...s found repair as necessary Did the terminal require replacement Verify repair Go to Step 14 11 1 Check for a poor connection at the MAP sensor 2 If a problem is found repair as necessary Was a proble...

Page 1014: ...manifold absolute pressure at or below 11 kPa for a total of approximately 10 seconds over a 16 second period D Ignition voltage more than 11 volts Action Taken When the DTC Sets D The PCM will illumi...

Page 1015: ...ds data 3 Operate the vehicle within Failure Records conditions as noted 4 Using a Tech 2 monitor DTC info for DTC P0107 Does the Tech 2 indicate DTC P0107 failed Go to Step 4 Refer to Diagnostic Aids...

Page 1016: ...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 Did the terminal require replacement Verify repair Go to Step...

Page 1017: ...ifold absolute pressure above 80 kPa for a total of approximately 10 seconds over a 16 second period Action Taken When the DTC Sets D The PCM will illuminate the malfunction indicator lamp MIL the fir...

Page 1018: ...rds conditions as noted 4 Using a Tech 2 monitor DTC info for DTC P0108 Does the Tech 2 indicate DTC P0108 failed this ignition Go to Step 4 Refer to Diagnostic Aids 4 1 Ignition OFF 2 Disconnect the...

Page 1019: ...s a condition found and corrected Verify repair Go to Step 11 11 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control Module and Sensors f...

Page 1020: ...luminate the malfunction indicator lamp MIL the first time the fault is detected D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data...

Page 1021: ...able 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...

Page 1022: ...tion Refer to Diagnostic Aids 4 1 Ignition OFF 2 Disconnect the IAT sensor electrical connector 3 Ignition ON 4 Observe the intake air temperature on the Tech 2 Is the intake air temperature below the...

Page 1023: ...or lamp MIL the first time the fault is detected D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data Conditions for Clearing the MIL...

Page 1024: ...s No 1 Was the On Board Diagnostic OBD System Check performed Go to Step 2 Go to OBD System Check 2 Ignition ON engine OFF Observe the Intake Air Temp display on the Tech 2 Is the Intake Air Temp belo...

Page 1025: ...al 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 circu...

Page 1026: ...e default value is based on start up intake air temperature and running time D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data Con...

Page 1027: ...le may be used to test the ECT sensor at various temperatures to evaluate the possibility of a shifted sensor that may be shorted above or below a certain temperature If this is the case replace the E...

Page 1028: ...sconnect the ECT sensor electrical connector 2 Observe the Eng Cool Temp display on the Tech 2 Is the Eng Cool Temp at the specified value 39 C 38 F Go to Step 6 Go to Step 5 5 1 Ignition OFF 2 Discon...

Page 1029: ...air temperature and running time D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data Conditions for Clearing the MIL DTC D The PCM...

Page 1030: ...the On Board Diagnostic OBD System Check performed Go to Step 2 Go to OBD System Check 2 1 Ignition ON engine OFF 2 Observe the Eng Cool Temp display on the Tech 2 Is the Eng Cool Temp below the spec...

Page 1031: ...t 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 terminal s if necessary Did...

Page 1032: ...esent D Engine is running D Vehicle speed is greater than 5 mph 8 km h D Intake air temperature is greater than 10 C 14 F 0 C 32 F D Start up engine coolant temperature is between 10 C 14 F and 28 C 8...

Page 1033: ...ne 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 actu...

Page 1034: ...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 Was a problem found Go to Step 10 Go to...

Page 1035: ...ter the second consecutive trip in which the fault is detected D The PCM will store condition which were present when the DTC was set as Freeze Frame and in the Failure Records data Conditions for Cle...

Page 1036: ...tors 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 information included in the Faillure Records data...

Page 1037: ...record Tech 2 Failure Records 3 Opreate the vehicle within Failure Records conditions as noted 4 Using a Tech 2 monitor DTC info for DTC P0128 Does the Tech 2 indicate DTC P0128 failed this ignition...

Page 1038: ...k 1 HO2S 1 signal voltage remains below 22 mV during normal closed loop operation for a total of 77 seconds over a 90 second period of time Action Taken When the DTC Sets D The PCM will illuminate the...

Page 1039: ...mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs This may assist in diagnosing the condition DTC P0131 HO2S Circuit Low Vol...

Page 1040: ...d 3 Ignition ON Does the Tech 2 indicate Bank 1 HO2S 1 voltage between the specified values 425 475 mV Refer to Diagnostic Aids Go to Step 9 9 Replace the PCM IMPORTANT The replacement PCM must be pro...

Page 1041: ...r a total of 77 seconds over a 90 second period OR D Bank 1 HO2S 1 signal voltage remains above 500 mV during deceleration fuel cutoff mode operation for 3 seconds Action Taken When the DTC Sets D The...

Page 1042: ...of the above conditions are present replace the affected HO2S Test Description Number s below refer to the step number s on the Diagnostic Chart 3 DTC P0132 failing during deceleration fuel cutoff mod...

Page 1043: ...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 Is Bank 1 HO2S 1 voltage between the specified values...

Page 1044: ...in closed loop D Engine has been running for at least 1 minute 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 4...

Page 1045: ...f 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 Thi...

Page 1046: ...tep 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 Is the action complete Go to Step 2 6 Check fo...

Page 1047: ...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 Bef...

Page 1048: ...D Oxygen sensor heaters are required by post catalyst monitor sensors to maintain a sufficiently high temperature for accurate exhaust oxygen content readings further from the engine Conditions for Se...

Page 1049: ...be set occurs This may assist in diagnosing the condition DTC P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1 Step Action Value s Yes No 1 Was the On Board Diagnostic OBD System Check perfor...

Page 1050: ...engine OFF 2 Disconnect Bank 1 HO2S 1 and jumper the HO2S high and low circuits PCM side to ground 3 Using a Tech 2 monitor Bank 1 HO2S 1 voltage Is Bank 1 HO2S 1 voltage in the specified range 0 10...

Page 1051: ...e is based on the accumulated amount of air that has passed through the MAF sensor and into the engine more accumulated air flow shorter time to HO2S activity Conditions for Setting the DTC D No relat...

Page 1052: ...heater ground circuit is faulty 5 Checks the HO2S heater ground circuit 6 Checks or an open or shorted HO2S heater element 10 An open HO2S signal or low circuit can cause the HO2S heater to appear fa...

Page 1053: ...igh or low circuit terminal connection at the Bank 1 HO2S 1 harness connector and replace terminal s if necessary Did any terminals require replacement Verify repair Go to Step 11 11 1 Ignition OFF 2...

Page 1054: ...etween 3 and 19 D Bank 1 HO2S 2 signal voltage remains below 22 mV during normal closed loop operation for a total of 106 seconds over a 125 second period of time OR D Bank 1 HO2S 2 signal voltage rem...

Page 1055: ...ittent condition is indicated Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs This m...

Page 1056: ...d 3 Ignition ON Does the Tech 2 indicate Bank 1 HO2S 2 voltage near the specified value 425 475 mV Refer to Diagnostic Aids Go to Step 9 9 Replace the PCM IMPORTANT The replacement PCM must be program...

Page 1057: ...0 F D Throttle angle is between 3 and 19 D Bank 1 HO2S 2 signal voltage remains above 952 mV during normal closed loop operation for a total of 106 seconds over a 125 second period of time OR D Bank 1...

Page 1058: ...mited within a range between 300 mV to 600 mV check the HO2S signal and wiring and associated terminal connections D If none of the above conditions are present replace the affected HO2S Test Descript...

Page 1059: ...ied value 10 mV Go to Step 7 Go to Step 8 7 1 Disconnect the jumpers to ground from Bank 1 HO2S 2 PCM side connector 2 With the HO2S 2 connector disconnected monitor BANK 1 HO2S 2 voltage Is the Bank...

Page 1060: ...will be set Heated oxygen sensors are used to minimize the amount of time required for closed loop fuel control operation and to allow accurate catalyst monitoring The oxygen sensor heater greatly de...

Page 1061: ...urs This may assist in diagnosing the condition DTC P0140 HO2S Circuit Insufficient Activity BANK 1 SENSOR 2 Step Action Value s Yes No 1 Was the On Board Diagnostic OBD System Check performed Go to S...

Page 1062: ...N engine OFF 2 Disconnect Bank 1 HO2S 2 and jumper the HO2S high and low circuits PCM side to ground 3 Using a Tech 2 monitor Bank 1 HO2S 2 voltage Is Bank 1 HO2S 2 voltage in the specified range 0 10...

Page 1063: ...ature is based on the total amount of air that has passed through the MAF sensor and into the engine more total airflow shorter time to HO2S activity Conditions for Setting the DTC D No related DTCs D...

Page 1064: ...ht should be connected to a good chassis ground in case the HO2S low or HO2S heater ground circuit is faulty 5 This checks the HO2S heater ground circuit 6 This checks for an open or shorted HO2S heat...

Page 1065: ...2 Disconnect the PCM and check the continuity of the Bank 1 HO2S 2 signal circuit and the Bank 1 HO2S 2 low circuit 3 If the Bank 1 HO2S 2 signal circuit or the HO2S low circuit measures over 5 ohms...

Page 1066: ...Bank 2 HO2S 1 signal voltage remains below 22 mV during normal closed loop operation for a total of 77 seconds over a 90 second period of time Action Taken When the DTC Sets D The PCM will illuminate...

Page 1067: ...e mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs This may assist in diagnosing the condition DTC P0151 HO2S Circuit Low V...

Page 1068: ...3 Ignition ON Does the Tech 2 indicate Bank 2 HO2S 1 voltage near the specified value 425 475 mV Refer to Diagnostic Aids Go to Step 9 9 Replace the PCM IMPORTANT The replacement PCM must be programm...

Page 1069: ...econds over a 90 second period OR D Bank 2 HO2S 1 signal voltage remains above 500 mV during deceleration fuel cutoff mode operation for up to 3 seconds Action Taken When the DTC Sets D The PCM will i...

Page 1070: ...D If none of the above conditions are present replace the affected HO2S Test Description Number s below refer to the step number s on the Diagnostic Chart 3 DTC P0152 failing during deceleration fuel...

Page 1071: ...1 Disconnect the jumpers to ground from Bank 2 HO2S 1 PCM side connector 2 With the HO2S 1 connector disconnected monitor Bank 2 HO2S 1 voltage Is the Bank 2 HO2S 1 voltage between the specified valu...

Page 1072: ...ng in closed loop D Engine has been running for at least one minute D Canister purge duty cycle is above 2 D Engine speed is between 1500 RPM and 3000 RPM D Mass air flow is between 9 g second and 42...

Page 1073: ...on of the fault Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs This may assist in d...

Page 1074: ...o 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 joint Is your action complete Go to Step 2 6 Check...

Page 1075: ...e 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 the sensors the caus...

Page 1076: ...d Bank 2 HO2S 1 to become active Oxygen sensor heaters are required by post catalyst monitor sensors to maintain a sufficiently high temperature for accurate exhaust oxygen content readings further fr...

Page 1077: ...icated 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...

Page 1078: ...ir open or poor connection as necessary Was a Bank 2 HO2S 1 low circuit problem found and corrected Verify repair Go to Step 9 9 1 Ignition ON engine OFF 2 Disconnect Bank 2 HO2S 1 and jumper the HO2S...

Page 1079: ...is based on the total amount of air that has passed through the mass air flow MAF sensor and into the engine more total air flow shorter time to HO2S activity Conditions for Setting the DTC D No relat...

Page 1080: ...should be connected to a good chassis ground in case the HO2S low or HO2S heater ground circuit is faulty 5 Checks the HO2S heater ground circuit 6 Checks for an open or shorted HO2S heater element 1...

Page 1081: ...erify repair Go to Step 10 10 Check for a poor Bank 2 HO2S 1 signal or low circuit terminal connection at the Bank 2 HO2S 1 harness connector and replace terminal s if necessary Did any terminals requ...

Page 1082: ...r more active than that produced by the Bank 2 HO2S 2 sensor If the Bank 2 HO2S 2 signal voltage remains excessively low for an extended period of time DTC P0157 will be set Conditions for Setting the...

Page 1083: ...ontamination D If none of above conditions are present replace the affected HO2S 2 Test Description Number s below refer to the step number s on the Diagnostic Chart 3 DTC P0157 failing during operati...

Page 1084: ...Is the action complete Verify repair 8 1 Ignition OFF 2 Reconnect the PCM leave HO2S 2 disconnected 3 Ignition ON Does the Tech 2 indicate Bank 2 HO2S 2 voltage near the specified value 425 475 mV Re...

Page 1085: ...ll be far more active than that produced by the Bank 2 HO2S 2 sensor If the Bank 2 HO2S 2 signal voltage remains excessively high for an extended period of time DTC P0158 will be set Conditions for Se...

Page 1086: ...operation An HO2S which is faulty and does not allow full voltage swing between the rich and lean thresholds can also cause this condition Operate the vehicle while monitoring the HO2S voltage with a...

Page 1087: ...gnal circuits PCM side to ground 3 Using a Tech 2 monitor Bank 2 HO2S 2 voltage Is Bank 2 HO2S 2 voltage below the specified value 10 mV Go to Step 7 Go to Step 8 7 1 Disconnect the jumpers to ground...

Page 1088: ...00 mV and 500 mV for an extended period of time DTC P0160 will be set Heated Oxygen sensors are used to minimize the amount of time required for closed loop fuel control operation and allow accurate c...

Page 1089: ...n intermittent condition is indicated Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occur...

Page 1090: ...r open or poor connections as necessary Was a Bank 2 HO2S 2 low circuit problem found and corrected Verify repair Go to Step 9 9 1 Ignition ON engine OFF 2 Disconnect Bank 2 HO2S 2 and jumper the HO2S...

Page 1091: ...perature is based on the total amount of air that has passed through the MAF sensor and into the engine more total air flow shorter time to HO2S activity Conditions for Setting the DTC D No related DT...

Page 1092: ...ground circuit is faulty 5 This checks the HO2S heater ground circuit 6 This checks for an open or shorted HO2S heater element 11 An open HO2S signal or low circuit can cause the HO2S heater to appear...

Page 1093: ...it and the Bank 2 HO2S 2 low circuit 3 If the Bank 2 HO2S 2 signal circuit or HO2S low circuit measures over 5 ohms repair the open or poor connection as necessary Was a problem found Verify repair Go...

Page 1094: ...status of the fuel trim diagnostic Conditions for Setting the DTC D No Tech 2 test is being run D None of the following EGR DTCs HO2S DTCs response transition open low volts no activity MAF DTCs TP s...

Page 1095: ...harness A change in the display will indicate the location of the fault Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition t...

Page 1096: ...f a driveability symptom still exists refer to Symptoms 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 i...

Page 1097: ...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...

Page 1098: ...ion and 20 The PCM s maximum authority to control short term fuel trim allows a range between 11 and 20 The PCM monitors fuel trim under various engine speed load fuel trim cells before determining th...

Page 1099: ...ng the condition which caused the other DTC will most likely correct the DTC P0172 P0175 4 If the DTC P0172 test passes while the Failure Records conditions are being duplicated the rich condition is...

Page 1100: ...l 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...

Page 1101: ...es a problem repair as necessary refer to Fuel Metering System Did the Injector Balance Test isolate a problem requiring repair Verify repair Go to Step 20 20 1 Remove and visually physically inspect...

Page 1102: ...ing the status of the fuel trim diagnostic Conditions for Setting the DTC D No Tech 2 test is being run D None of the following DTCs are set idle system EGR HO2S response transition open low volts no...

Page 1103: ...harness A change in the display will indicate the location of the fault Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition t...

Page 1104: ...result Does the Tech 2 indicate DTC P0174 failed this ignition Go to Step 5 The lean condition is not present If a driveability symptom still exists refer to Symptoms section 5 Was DTC P0171 also set...

Page 1105: ...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...

Page 1106: ...rs fuel trim under various engine speed load fuel trim cells before determining the status of the fuel trim diagnostic Conditions for Setting the DTC D No Tech 2 test is being run D None of the follow...

Page 1107: ...Symptoms for additional information on diagnosing intermittent problems DTC P0175 Fuel Trim System Rich Bank 2 Step Action Value s Yes No 1 Was the On Board Diagnostic OBD System Check performed Go t...

Page 1108: ...ire replacement Verify repair Go to Step 12 12 1 Ignition ON engine OFF 2 Monitor the TP Angle display on the Tech 2 while slowly depressing the accelerator pedal Does the TP Angle display increase st...

Page 1109: ...lates a problem repair as necessary refer to Fuel Metering System Did the Injector Balance Test isolate a problem requiring repair Verify repair Go to Step 20 20 1 Remove and visually physically inspe...

Page 1110: ...Sets D The PCM will illuminate the malfunction indicator lamp MIL the first time the fault is detected D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in t...

Page 1111: ...ge to the injector is OK but the driver circuit is grounded at all times This step determines if the circuit is shorted to ground or the PCM is faulty 9 The reading should be about 12 14m 10 Locating...

Page 1112: ...he 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...

Page 1113: ...Sets D The PCM will illuminate the malfunction indicator lamp MIL the first time the fault is detected D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in t...

Page 1114: ...ge to the injector is OK but the driver circuit is grounded at all times This step determines if the circuit is shorted to ground or the PCM is faulty 9 The reading should be about 12 14m 10 Locating...

Page 1115: ...injector side of the harness connect an ohmmeter between the positive wire red with blue tracer and the wire for cylinder 2 green with orange tracer Does the ohmmeter indicate continuity Go to Step 1...

Page 1116: ...DTC Sets D The PCM will illuminate the malfunction indicator lamp MIL the first time the fault is detected D The PCM will store conditions which were present when the DTC was set as Freeze Frame and i...

Page 1117: ...ge to the injector is OK but the driver circuit is grounded at all times This step determines if the circuit is shorted to ground or the PCM is faulty 9 The reading should be about 12 14m 10 Locating...

Page 1118: ...ctor 2 At the injector side of the harness connect an ohmmeter between the positive wire red with blue tracer and the wire for cylinder 3 green Does the ohmmeter indicate continuity Go to Step 11 Go t...

Page 1119: ...DTC Sets D The PCM will illuminate the malfunction indicator lamp MIL the first time the fault is detected D The PCM will store conditions which were present when the DTC was set as Freeze Frame and i...

Page 1120: ...ge to the injector is OK but the driver circuit is grounded at all times This step determines if the circuit is shorted to ground or the PCM is faulty 9 The reading should be about 12 14m 10 Locating...

Page 1121: ...2 At the injector side of the harness connect an ohmmeter between the positive wire red with blue tracer and the wire for cylinder 4 green red Does the ohmmeter indicate continuity Go to Step 11 Go t...

Page 1122: ...inate the malfunction indicator lamp MIL the first time the fault is detected D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data Co...

Page 1123: ...ge to the injector is OK but the driver circuit is grounded at all times This step determines if the circuit is shorted to ground or the PCM is faulty 9 The reading should be about 12 14m 10 Locating...

Page 1124: ...e injector side of the harness connect an ohmmeter between the positive wire red with blue tracer and the wire for cylinder 5 green with black tracer Does the ohmmeter indicate continuity Go to Step 1...

Page 1125: ...C Sets D The PCM will illuminate the malfunction indicator lamp MIL the first time the fault is detected D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in...

Page 1126: ...ge to the injector is OK but the driver circuit is grounded at all times This step determines if the circuit is shorted to ground or the PCM is faulty 9 The reading should be about 12 14m 10 Locating...

Page 1127: ...injector side of the harness connect an ohmmeter between the positive wire red with blue tracer and the wire for cylinder 6 green with yellow tracer Does the ohmmeter indicate continuity Go to Step 1...

Page 1128: ...Substitute a known good coil Swap the ignition coils and retest If the misfire follows the coil replace the ignition coil If the misfire is random check for the following conditions D System grounds...

Page 1129: ...e EGR feed pipes D ION Sensing Module 2 If a problem is found repair the vacuum leak as necessary Did your inspection reveal a vacuum leak Verify repair Go to Step 5 5 1 Visually and physically inspec...

Page 1130: ...k plug s as necessary Did your inspection reveal a problem Verify repair Go to Step 12 12 1 Disconnect the MAF sensor electrical connector 2 Operate the vehicle in closed loop while monitoring the BAN...

Page 1131: ...ct camshaft D Leaking or sticky valves or rings D Excessive valve deposits D Weak valve springs D Incorrect valve timing D A leaking head gasket D A loose or broken motor mount 2 If a problem is found...

Page 1132: ...by disconnecting the PCM battery feed Diagnostic Aids Check for the following conditions D System grounds Ensure all connections are clean and properly tightened D Injector Perform the injector coil...

Page 1133: ...inatio n Diagnosis chart in Engine Mechanical Diagnosis Go to Step 9 9 1 Visually inspect the spark plug insulator for cracks carbon tracking or other damage 2 If the spark plug is damaged replace the...

Page 1134: ...onnecting the PCM battery feed Diagnostic Aids Check for the following conditions D System grounds Ensure all connections are clean and properly tightened D Injector Perform the injector coil balance...

Page 1135: ...inatio n Diagnosis chart in Engine Mechanical Diagnosis Go to Step 9 9 1 Visually inspect the spark plug insulator for cracks carbon tracking or other damage 2 If the spark plug is damaged replace the...

Page 1136: ...onnecting the PCM battery feed Diagnostic Aids Check for the following conditions D System grounds Ensure all connections are clean and properly tightened D Injector Perform the injector coil balance...

Page 1137: ...inatio n Diagnosis chart in Engine Mechanical Diagnosis Go to Step 9 9 1 Visually inspect the spark plug insulator for cracks carbon tracking or other damage 2 If the spark plug is damaged replace the...

Page 1138: ...onnecting the PCM battery feed Diagnostic Aids Check for the following conditions D System grounds Ensure all connections are clean and properly tightened D Injector Perform the injector coil balance...

Page 1139: ...inatio n Diagnosis chart in Engine Mechanical Diagnosis Go to Step 9 9 1 Visually inspect the spark plug insulator for cracks carbon tracking or other damage 2 If the spark plug is damaged replace the...

Page 1140: ...onnecting the PCM battery feed Diagnostic Aids Check for the following conditions D System grounds Ensure all connections are clean and properly tightened D Injector Perform the injector coil balance...

Page 1141: ...inatio n Diagnosis chart in Engine Mechanical Diagnosis Go to Step 9 9 1 Visually inspect the spark plug insulator for cracks carbon tracking or other damage 2 If the spark plug is damaged replace the...

Page 1142: ...disconnecting the PCM battery feed Diagnostic Aids Check for the following conditions D System grounds Ensure all connections are clean and properly tightened D Injector Perform the injector coil bal...

Page 1143: ...gnosis chart in Engine Mechanical Diagnosis Go to Step 9 9 1 Visually inspect the spark plug insulator for cracks carbon tracking or other damage 2 If the spark plug is damaged replace the spark plug...

Page 1144: ...e fault is detected D The PCM calculates an air flow value based on idle air control valve position throttle position RPM and barometric pressure D The PCM will store condition which were present when...

Page 1145: ...r to Diagnostic Aids 3 1 Ignition OFF 2 Disconnect the ION sensing module 3 Disconnect the PCM Is the action complete Go to Step 4 4 Check the ION sensing harness between the PCM F68 and ION sensing m...

Page 1146: ...tion complete Verify repair Go to Step 10 11 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 re...

Page 1147: ...et Conditions for Setting the DTC D Engine is running D Extra or missing pulse is detected between consecutive 58X reference pulses D Above condition is detected in 10 of 100 crankshaft rotations Acti...

Page 1148: ...onnection D Damaged harness Inspect the wiring harness for damage If the harness appears to be OK disconnect the PCM turn the ignition on and observe a voltmeter connected to the 58X reference circuit...

Page 1149: ...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...

Page 1150: ...reference circuit DTC P0337 will set Conditions for Setting the DTC D No camshaft position CMP sensor DTCs are set D Engine cranking D Crankshaft position CKP sensor signal is not present between two...

Page 1151: ...Step 2 Go to OBD System Check 2 Attempt to start the engine Does the engine start Go to Step 3 Go to Chart 3 3 1 Review and record Failure Records information 2 Clear DTC P0337 3 Start the engine and...

Page 1152: ...drip out Is the action complete Verify repair 11 Check the connections at the PCM and replace the terminals if necessary Did any terminals require replacement Verify repair Go to Step 12 12 Replace t...

Page 1153: ...iate injector sequence without the CMP signal with a one in six chance that injector sequence is correct The engine will continue to start and run normally although the misfire diagnostic will be affe...

Page 1154: ...al to wire connection D Damaged harness Inspect the wiring harness for damage If the harness appears to be OK disconnect the PCM turn the ignition on and observe a voltmeter connected to the CMP signa...

Page 1155: ...4 6 V Go to Step 11 Go to Step 8 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 re...

Page 1156: ...ve 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...

Page 1157: ...the PCM does not receive pulses on the CMP reference circuit DTC P0342 will set and the PCM will initiate injector sequence without the CMP signal with a one in six chance that injector sequence is co...

Page 1158: ...step number s on the Diagnostic Chart 2 Ensures that the fault is present 14 Determines whether the fault is being caused by a damaged camshaft or a faulty PCM The voltage measured in this step should...

Page 1159: ...e 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...

Page 1160: ...spond to this test Does the DVM display a voltage near the specified value 0 V Go to Step 14 Go to Step 13 13 Replace the camshaft position sensor Is the action complete Verify repair 14 Replace the P...

Page 1161: ...The ignition is ON D The engine is turning determined by the 58X crankshaft position input signal D The output voltage is not equal to 5 volts when output is ON D The output voltage is not equal to 0...

Page 1162: ...5 Note the test result Does the Tech 2 indicate DTC P0351 failed this ignition cycle Go to Step 3 Go to Diagnostic Aids 3 Check for faulty connection at ignition coil Was a problem found Verify repai...

Page 1163: ...3 12 Repair the open ignition control circuit Is the action complete Verify repair 13 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control...

Page 1164: ...The ignition is ON D The engine is turning determined by the 58 X crankshaft position input signal D The output voltage is not equal to 5 volts when output is ON D The output voltage is not equal to...

Page 1165: ...Note the test result Does the Tech 2 indicate DTC P0352 failed this ignition cycle Go to Step 3 Go to Diagnostic Aids 3 Check for faulty connection at ignition coil Was a problem found Verify repair G...

Page 1166: ...3 12 Repair the open ignition control circuit Is the action complete Verify repair 13 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control...

Page 1167: ...The ignition is ON D The engine is turning determined by the 58X crankshaft position input signal D The output voltage is not equal to 5 volts when output is ON D The output voltage is not equal to 0...

Page 1168: ...lt Does the Tech 2 indicate DTC P0353 failed this ignition cycle Go to Step 3 Go to Diagnostic Aids 3 Check for faulty connection at ignition coil Was a problem found Verify repair Go to Step 4 4 Chec...

Page 1169: ...3 12 Repair the open ignition control circuit Is the action complete Verify repair 13 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control...

Page 1170: ...The ignition is ON D The engine is turning determined by the 58X crankshaft position input signal D The output voltage is not equal to 5 volts when output is ON D The output voltage is not equal to 0...

Page 1171: ...lt Does the Tech 2 indicate DTC P0354 failed this ignition cycle Go to Step 3 Go to Diagnostic Aids 3 Check for faulty connection at ignition coil Was a problem found Verify repair Go to Step 4 4 Chec...

Page 1172: ...12 Repair the open in ignition control circuit Is the action complete Verify repair 13 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Contr...

Page 1173: ...D The ignition is ON D The engine is turning determined by the 58X crankshaft position input signal D The output voltage is not equal to 5 volts when output is ON D The output voltage is not equal to...

Page 1174: ...lt Does the Tech 2 indicate DTC P0355 failed this ignition cycle Go to Step 3 Go to Diagnostic Aids 3 Check for faulty connection at ignition coil Was a problem found Verify repair Go to Step 4 4 Chec...

Page 1175: ...3 12 Repair the open ignition control circuit Is the action complete Verify repair 13 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control...

Page 1176: ...e ignition is ON D The engine is turning determined by the 58X crankshaft position input signal D The output voltage is not equal to 5 volts when output is ON D The output voltage is not equal to 0 vo...

Page 1177: ...lt Does the Tech 2 indicate DTC P0356 failed this ignition cycle Go to Step 3 Go to Diagnostic Aids 3 Check for faulty connection at ignition coil Was a problem found Verify repair Go to Step 4 4 Chec...

Page 1178: ...3 12 Repair the open ignition control circuit Is the action complete Verify repair 13 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control...

Page 1179: ...or VSS MAP sensor EGR Pintle Position sensor ECT sensor misfire or automatic transmission DTCs set D Engine coolant temperature is greater than 60 C 140 F D Ignition voltage between 11 5 and 16 volts...

Page 1180: ...of excessive heat check the exhaust system for blockage possibly a plugged catalytic converter using the Restricted Exhaust System Check Test Description Number s below refer to the step number s on t...

Page 1181: ...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...

Page 1182: ...cords data Conditions for Clearing the MIL DTC D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present...

Page 1183: ...terminals Go to Step 4 Go to Step 5 4 Repair the damaged pin or terminal Is the action complete Verify repair 5 1 Remove EGR valve from Engine 2 Inspect EGR valve whether there is any foreign material...

Page 1184: ...D The PCM will illuminate the malfunction indicator lamp MIL as soon as failure detected after consecutive 2nd trip in which the fault is detected D The PCM will store conditions which were present wh...

Page 1185: ...pect 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...

Page 1186: ...on as failure detected D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in Failure Records data Conditions for Clearing the MIL DTC D The PCM will turn the M...

Page 1187: ...EL and ground Did the DVM indicate the specified value 4 6 V Go to Step 6 Go to Step 7 6 1 Disconnect the EGR harness connector 2 Measure resistance between terminal 5 Volt reference wire and ground W...

Page 1188: ...the EGR pintle position circuit and ground Is the measured voltage near the specified value Less than 0 1 V Go to Step 17 Go to Step 16 16 Check for a short circuit between other wires and the pintle...

Page 1189: ...etected D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in Failure Records data Conditions for Clearing the MIL DTC D The PCM will turn the MIL OFF on the t...

Page 1190: ...VM to check the voltage at the 5 volt reference wire RED YEL Did the DVM indicate the specified value 4 6 V Go to Step 8 Go to Step 6 6 1 Ignition ON 2 At the PCM connector backprove with a DVM at the...

Page 1191: ...e short circuit at EGR harness between RED YEL to RED YEL or GRN YEL RED to BLK YEL 2 Replace EGR harness Is the action complete Verify repair 14 Replace EGR harness Is the action complete Verify repa...

Page 1192: ...catalyst s oxygen storage capacity is below the acceptable threshold D Intake Air temperature is between 10 C 14 F and 70 C 158 F Action Taken When the DTC Sets D The PCM will illuminate the malfunct...

Page 1193: ...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 ac...

Page 1194: ...HO2S 2 2 Ensure that the Bank 1 HO2S 2 is secure and that the pigtail and wiring harness is not contacting the exhaust pipe or is not otherwise damaged 3 If a problem is found repair as necessary Did...

Page 1195: ...S 2 sensor If the PCM detects a level of Bank 2 HO2S 2 activity that indicates the catalyst is no longer operating efficiently DTC P0430 will be set Conditions for Setting the DTC D No related DTCs D...

Page 1196: ...y 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...

Page 1197: ...O2S 2 2 Ensure that the Bank 2 HO2S 2 is secure and that the pigtail and wiring harness is not contacting the exhaust pipe or is not otherwise damaged 3 If a problem is found repair as necessary Did y...

Page 1198: ...following conditions D Disconnected or faulty fuel tank pressure sensor D Missing or faulty fuel cap D Disconnected damaged pinched or blocked EVAP purge line D Disconnected or damaged EVAP vent hose...

Page 1199: ...tion that caused the DTC to be set occurs This may assist in diagnosing the condition Test Description Number s below refer to the step number s on the Diagnostic Chart 2 If an EVAP canister vent sole...

Page 1200: ...r line D Restricted EVAP purge line 2 If a problem is found repair as necessary Was a problem found Verify repair Go to DTC P0452 or DTC P0453 7 1 Visually physically check for the following condition...

Page 1201: ...vel over a given time period all other variables remaining constant A small leak in the system will cause DTC P0442 to be set Conditions for Setting the DTC D No TP sensor ECT sensor Tank pressure sen...

Page 1202: ...alue s Yes No 1 Was the On Board Diagnostic OBD System Check performed Go to Step 2 Go to OBD System Check 2 1 Ignition OFF 2 Remove the fuel cap 3 Ignition ON 4 Observe Fuel Tank Pressure on the Tech...

Page 1203: ...or the following conditions D Missing or faulty fuel cap D Disconnected or leaking fuel tank vapor line D Disconnected or damaged EVAP purge line 2 If a problem is found repair as necessary Was a prob...

Page 1204: ...nt solenoid stuck closed D Plugged kinked or pinched vent hose D Shorted EVAP canister vent solenoid driver circuit D Plugged evaporative canister If any of these conditions are present DTC P0446 will...

Page 1205: ...bient pressure 4 Verifies that the fuel tank pressure sensor accurately reacts to EVAP system pressure changes 6 Checks for a blocked EVAP canister DTC P0446 EVAP Canister Vent Blocked Step Action Val...

Page 1206: ...nister vent solenoid for kinks pinched areas or any other form of blockage 2 If a problem is found repair as necessary Was a problem found Go to Step 9 Go to Step 7 7 Replace the EVAP canister vent so...

Page 1207: ...ng the MIL DTC D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present D A history DTC P0402 will clea...

Page 1208: ...to Step 4 Go to Step 10 4 1 Ignition OFF 2 Connect the PCM connector to the PCM 3 Backprobe with a DVM at fuel tank pressure sensor between 5 V reference terminal and sensor ground terminal Was the v...

Page 1209: ...the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control Module and Sensors for procedures And also refer to latest Service Bulletin Check to see if t...

Page 1210: ...a Conditions for Clearing the MIL DTC D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present D A hist...

Page 1211: ...o Step 4 Go to Step 10 4 1 Ignition OFF 2 Connect the PCM connector to the PCM 3 Disconnect sensor harness at fuel pressure sensor Measure voltage with a DVM at the end of the tank pressure wiring bet...

Page 1212: ...ce the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control Module and Sensors for procedures And also refer to latest Service Bulletin Check to see i...

Page 1213: ...e in vacuum level over a given time period all other variables remaining constant A very small leak in the system will cause DTC P0456 to be set Conditions for setting the DTC D No MAP DTC s set D No...

Page 1214: ...Ignition OFF 2 Remove the fuel cap 3 Ignition ON 4 Observe Fuel Tank Pressure on the Tech 2 Does the Tech 2 indicate Fuel Tank Pressure at the specified value 1 51V Go toStep 3 Go toFuel Tank Pressure...

Page 1215: ...ery Small Leak Cont d Step No Yes Value s Action 7 1 Visually physically check for the following conditions D Disconnected or leaking fuel tank vapor line D Disconnected or damage EVAP purge line 2 If...

Page 1216: ...e connection DTC P0462 is set Conditions for Setting the DTC D Fuel tank level slosh test is completed D Fuel tank level main test is completed D Fuel tank level data is valid D Fuel tank level signal...

Page 1217: ...E 348 TROOPER 6VE1 3 5L ENGINE DRIVEABILITY AND EMISSIONS Test Description Number s below refer to the step number s on the Diagnostic Chart 8 The following chart can be used to check the sending unit...

Page 1218: ...ly 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...

Page 1219: ...is shorted to ground DTC P0463 is set Conditions for Setting the DTC D Fuel tank level slosh test is completed D Fuel tank level main test is completed D Fuel tank level data is valid D Fuel tank leve...

Page 1220: ...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 pos...

Page 1221: ...lfunction indicator lamp MIL the first time the fault is detected D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data Conditions for...

Page 1222: ...n ON sensor disconnected 2 Using a DVM measure at the VSS connector between ground and voltage supply Was the measurement near the specified value Battery voltage Go to Step 7 Go to Step 6 6 Repair th...

Page 1223: ...rner 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 Ra...

Page 1224: ...Engine coolant temperature ECT is above 50 C D Ignition voltage is between 9 5 volts and 16 7 volts D The throttle is closed D EVAP purge duty cycle more than 10 D All conditions are met for 10 second...

Page 1225: ...le plate D Throttle body with lever Check for objects send round the throttle spring lever that lever is smooth movement and spring lever has not excessive play Do any of the above require a repair Re...

Page 1226: ...ND 4 6km SIG DND change resistance Verify repair Go toStep 8 8 Replace the acceleration position sensor Is the action complete Go toStep 9 9 Following below the DTCs stored P1125 P1290 P1295 P1299 Go...

Page 1227: ...is between 9 5 volts and 16 7 volts D The throttle is closed D EVAP purge duty cycle is more than 10 D All conditions are met for 10 seconds D Engine speed is more than 100 200 RPM higher than desire...

Page 1228: ...bore and on the throttle plate D Throttle body with lever Check for objects send round the throttle spring lever that lever is smooth movement and spring lever has not excessive play Do any of the abo...

Page 1229: ...GND 4 6km SIG DND change resistance Verify repair Go to Step 8 8 Replace the acceleration position sensor Is the action complete Go to Step 9 9 Following below the DTCs stored P1125 P1290 P1295 P1299...

Page 1230: ...5 minutes Action Taken When the DTC Sets 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 Thi...

Page 1231: ...Go to Starting Char ging 4 1 Ignition OFF 2 Disconnect the PCM connector at the PCM 3 Using a DVM measure the battery voltage at the PCM connector F 20 and F 57 Is it approximately equal to battery v...

Page 1232: ...inutes Action Taken When the DTC Sets D The PCM will not illuminate the malfunction indicator lamp MIL D The PCM will store as Failure Records only conditions which were present when the DTC was set T...

Page 1233: ...specified value 11 5 V Replace battery Go to Step 4 4 1 Turn OFF all the accessories 2 Install a Tech 2 3 Select the ignition voltage parameter on the Tech 2 4 Start the engine and raise the engine RP...

Page 1234: ...PCM detects an internal program fault check sum error Action Taken When the DTC Sets D The PCM will not illuminate the malfunction indicator lamp MIL D The PCM will store conditions which were presen...

Page 1235: ...to OBD System Check 2 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control Module and Sensors for procedures ANd also refer to latest Ser...

Page 1236: ...TC Sets D The PCM will not illuminate the malfunction indicator lamp MIL D The PCM will store conditions which were present when the DTC was set in the Failure Records data only Conditions for Clearin...

Page 1237: ...p 2 Go to OBD System Check 2 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control Module and Sensors for procedures ANd also refer to late...

Page 1238: ...will not illuminate the malfunction indicator lamp MIL D The PCM will store conditions which were present when the DTC was set in the Failure Records data only Conditions for Clearing the MIL DTC D T...

Page 1239: ...Go to OBD System Check 2 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control Module and Sensors for procedures ANd also refer to latest S...

Page 1240: ...ntly control up to 7 outputs Conditions for Setting the DTC D This code detects inconsistencies between Main CPU A D converters and Watchdog CPU A D converters Action Taken When the DTC Sets D The PCM...

Page 1241: ...ep 2 Go to OBD System Check 2 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control Module and Sensors for procedures ANd also refer to lat...

Page 1242: ...eed is below 1000 RPM D Throttle angle is below 10 if engine speed is above 1000 RPM D The MAP sensor indicates an intermittent manifold absolute pressure above 80 kPa for a total of approximately 5 s...

Page 1243: ...o to Step 6 Go to Step 4 4 Check for a poor sensor ground circuit terminal connection at the MAP sensor Was a problem found Go to Step 9 Go to Step 5 5 Check the MAP signal circuit between the MAP sen...

Page 1244: ...ngle is above 2 if engine speed is above 1000 RPM D The MAP sensor indicates an intermittent manifold absolute pressure below 11 kPa for a total of approximately 5 seconds over a 16 second period of t...

Page 1245: ...signal circuit between the MAP sensor connector and the PCM for an intermittent open or short to ground Was a problem found Go to Step 9 Go to Step 7 5 Check for an intermittent short to ground on th...

Page 1246: ...y 2 5 seconds over a 25 second period of time Action Taken When the DTC Sets D The PCM will substitute a default value for intake air temperature D The PCM will store conditions which were present whe...

Page 1247: ...ILITY AND EMISSIONS Intake Air Temperature Sensor 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 12...

Page 1248: ...nd repair as necessary Was a problem found Verify repair Go to Step 6 6 1 Check the IAT signal circuit between the IAT sensor connector and the PCM for an intermittent open 2 If a problem is found rep...

Page 1249: ...on indicator lamp MIL D The PCM will store conditions which were present when the DTC was set as Failure Records data only This information will not be stored as Freeze Frame data D The PCM will subst...

Page 1250: ...emperature Sensor 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...

Page 1251: ...ut 0 10 volt for a total of 10 seconds over a 100 second period Action Taken When the DTC Sets D The PCM will not illuminate the malfunction indicator lamp MIL D The PCM will store conditions which we...

Page 1252: ...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 Step Action Value s Yes No 1 Was the On Board Diagnostic OBD System Check performed G...

Page 1253: ...out 5 volts for a total of 10 seconds over a 100 second period Action Taken When the DTC Sets D The PCM will not illuminate the malfunction indicator lamp MIL D The PCM will store conditions which wer...

Page 1254: ...DTC to be set occurs This may assist in diagnosing the condition Engine Coolant Temperature Sensor C F OHMS Temperature vs Resistance Values approximate 100 212 177 80 176 332 60 140 667 45 113 1188 3...

Page 1255: ...nd repair as necessary Was a problem found Verify repair Go to Step 6 6 1 Check the ECT signal circuit between the ECT sensor connector and the PCM for an intermittent open 2 If a problem is found rep...

Page 1256: ...D A histror DTC P1120 will clear after 40 cosecutive trip cycle during which the warm up cycles have occurred without a fault D DTC P1120 can be cleared using the Tech 2 Clear Info function or by disc...

Page 1257: ...rted Verify repair Go to Step 12 5 Replace the MAP sensor Is the action complete Verify repair 6 Observe the TP angle reading on the Tech 2 while slowly opening the throttle Does the TP angle increase...

Page 1258: ...he TP sensor 3 If a problem is found repair wiring harness as necessary Was a problem found Verify repair Go to Step 12 11 Replace the TP sensor Is the action complete Verify repair 12 Replace the PCM...

Page 1259: ...utive trip cycle during which the warm up cycles have occurred without a fault D DTC P1125 can be cleared using the Tech 2 Clear Info function or by disconnecting the PCM battery feed Diagnostic Aids...

Page 1260: ...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 2 Observe the AP sensor reading on th...

Page 1261: ...plete Verify repair 9 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 B...

Page 1262: ...D Engine coolant temperature ECT is above 50 C 122 F for automatic transmission 75 C 167 F for manual transmission D Engine is operating in closed loop D The engine has been running at least one minut...

Page 1263: ...1 Was the On Board Diagnostic OBD System Check performed Go to Step 2 Go to OBD System Check 2 IMPORTANT If any DTCs are set except P1153 or P1154 refer to those DTCs before proceeding with this diagn...

Page 1264: ...ween 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 16 1 Ignition OFF 2 Check for...

Page 1265: ...on complete Verify repair 22 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control Module and Sensors for procedures And also refer to late...

Page 1266: ...engine has been running at least one minute D Canister purge duty cycle is greater than 2 D Engine speed is between 1500 RPM and 3000 RPM D Mass air flow MAF is between 9 g second and 42 g second D A...

Page 1267: ...NT If any DTCs are set except P1153 and or P1154 refer to those DTCs before proceeding with this diagnostic chart 1 Idle the engine at operating temperature 2 Operate the vehicle within parameters spe...

Page 1268: ...high signal circuit and ground 4 Also measure the voltage between the low signal circuit and ground Are both voltages in the specified range 3 4V Go to Step 16 Go to Step 19 16 1 With Bank 1 HO2S 1 d...

Page 1269: ...n complete Verify repair 22 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control Module and Sensors for procedures And also refer to lates...

Page 1270: ...ngine is operating in closed loop D Engine coolant temperature ECT is above 50 C 122 F for automatic transmission 75 C 167 F for manual transmission D The engine has been running at least one minute D...

Page 1271: ...o 1 Was the On Board Diagnostic OBD System Check performed Go to Step 2 Go to OBD System Check 2 IMPORTANT If any DTCs are set except P1133 and or P1134 refer to those DTCs before proceeding with this...

Page 1272: ...oltage 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 16 1 Ignition ON 2 Ch...

Page 1273: ...n complete Verify repair 22 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control Module and Sensors for procedures And also refer to lates...

Page 1274: ...s greater than 2 D Engine speed is between 1500 RPM and 3000 RPM D Mass air flow is between 9 g second and 42 g second D Above conditions are present for a 3 second monitoring period D 90 seconds afte...

Page 1275: ...before proceeding with this diagnostic chart 1 Idle the engine at operating temperature 2 Operate the vehicle within parameters specified under Conditions for Setting the DTC criteria included in Diag...

Page 1276: ...n 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 2 HO2S...

Page 1277: ...n complete Verify repair 22 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control Module and Sensors for procedures And also refer to lates...

Page 1278: ...r fuel control sensors Conditions for setting the DTC D No related DTCs D The engine coolant temperature is more than 60 C 140 F D Engine is operating in closed loop power enrichment mode for 3 second...

Page 1279: ...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 With the engine running is the fuel pressure with...

Page 1280: ...fuel control sensors Conditions for setting the DTC D No related DTCs D The engine coolant temperature is more than 60 C 140 F D Engine is operating in closed loop power enrichment mode for 3 seconde...

Page 1281: ...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 With the engine running is the fuel pressure with...

Page 1282: ...loop power enrichment mode for 3 seconds D Engine coolant temperature is above 60 C 140 F D While in power enrichment mode the oxygen sensor voltage remains below 400 mV for 3 seconds Action Taken Wh...

Page 1283: ...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 W...

Page 1284: ...ump relay and crank the engine to relieve the fuel pressure 2 Install the fuel pressure gauge 3 Start the engine and idle at normal operating temperature 4 Disconnect the vacuum line going to the fuel...

Page 1285: ...which the warm up cycles have occurred without a fault D DTC P1120 can be cleared using the Tech2 Clear Info function or by disconnecting the PCM battery feed Diagnostic Aids An intermittent may be c...

Page 1286: ...the circuit and see if 5V returns Go to Step 6 Go to Step 5 5 1 Check the MAP signal circuit between the PCM and MAP ground circuit 2 If the MAP signal circuit is open or shorted repair as necessary W...

Page 1287: ...cuit or 5 volt reference circuit for a poor connection 2 TP2 signal circuit or 5 volt reference circuit for high resistance between the PCM and the TP sensor 3 If a problem is found repair wiring harn...

Page 1288: ...or pedal arm with spring and excessive deposits in the acceleration pedal arm and on the acceleration pedal Test Description Number s below refer to the step number s on the Diagnostic Chart 2 Visual...

Page 1289: ...e above require a repair Refer to appropriate section for on vehicle service Go to Step 5 4 Visually physically inspect for the following conditions D Acceleration pedal tampering D Acceleration pedal...

Page 1290: ...as necessary Was a problem found Verify repair Go to Step 9 9 Replace the acceleration position sensor Is the action complete Go to Step 10 10 Following below the DTCs stored P1125 P1290 P1295 P1299...

Page 1291: ...will clear after 40 consecutive trip cycle during which the warm up cycles have occurred without a fault D DTC P1271 can be cleared using the Tech 2 Clear Info function or by disconnecting the PCM ba...

Page 1292: ...tep 6 5 1 Connect a test light between the 5 Voltge supply circuit and the AP sensor signal circuit at the AP1 AP2 sensor harness connector 2 Observe the AP sensor reading on the Tech 2 Is the AP sens...

Page 1293: ...he 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 lat...

Page 1294: ...will clear after 40 consecutive trip cycle during which the warm up cycles have occurred without a fault D DTC P1272 can be cleared using the Tech 2 Clear Info function or by disconnecting the PCM ba...

Page 1295: ...6 5 1 Connect a test light between the 5 Voltge supply circuit and the AP sensor signal circuit at the AP2 and AP3 sensor harness connector 2 Observe the AP sensor reading on the Tech 2 Is the AP sen...

Page 1296: ...e 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 late...

Page 1297: ...will clear after 40 consecutive trip cycle during which the warm up cycles have occurred without a fault D DTC P1273 can be cleared using the Tech 2 Clear Info function or by disconnecting the PCM ba...

Page 1298: ...5 1 Connect a test light between the 5 Voltge supply circuit and the AP sensor signal circuit at the AP1 and AP3 sensor harness connector 2 Observe the AP sensor reading on the Tech 2 Is the AP senso...

Page 1299: ...he 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 lat...

Page 1300: ...DTC P1275 will clear after 40 consecutive trip cycle during which the warm up cycles have occurred without a fault D DTC P1275 can be cleared using the Tech 2 Clear Info function or by disconnecting...

Page 1301: ...he AP sensor reading near the specified value 5V Go to Step 7 Go to Step 8 6 Check the following items 1 AP1 signal circuit for a short to voltage 2 AP1 sensor ground circuit for high resistance betwe...

Page 1302: ...DTC P1280 will clear after 40 consecutive trip cycle during which the warm up cycles have occurred without a fault D DTC P1280 can be cleared using the Tech 2 Clear Info function or by disconnecting...

Page 1303: ...he AP sensor reading near the specified value 5V Go to Step 7 Go to Step 8 6 Check the following items 1 AP2 signal circuit for a short to voltage 2 AP2 sensor ground circuit for high resistance betwe...

Page 1304: ...y DTC P1285 will clear after 40 consecutive trip cycle during which the warm up cycles have occurred without a fault D DTC P1285 can be cleared using the Tech 2 Clear Info function or by disconnecting...

Page 1305: ...he AP sensor reading near the specified value 5V Go to Step 7 Go to Step 8 6 Check the following items 1 AP3 signal circuit for a short to voltage 2 AP3 sensor ground circuit for high resistance betwe...

Page 1306: ...ring which the warm up cycles have occurred without a fault D DTC P1290 can be cleared using the Tech 2 Clear Info function or by disconnecting the PCM battery feed Diagnostic Aids An intermittent may...

Page 1307: ...V 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 2 Observe the AP sensor readin...

Page 1308: ...e Verify repair 9 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 Bulle...

Page 1309: ...ditects that if the systm is in PowerManagement Mode Fail safe Mode Conditions for setting the DTC D The ignition is ON D Power Management Mode is active Fail safe Mode Action Taken When the DTC Sets...

Page 1310: ...d 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 P1295 Does the Tech 2 indicate DTC P1295 failed this ign...

Page 1311: ...e TP1and TP2 sensor 3 If a problem is found repair wiring harness as necessary Was a problem found Verify repair Go to Step 14 13 Replace the TP sensor Is the action complete Verify repair 14 1 Start...

Page 1312: ...nosis chart forother sensors in the circuit and see if 5V returns Go to Step 22 Go to Step 21 21 1 Check the MAP signal circuit between the PCM and MAP grund circuit 2 If the MAP signal circuit is ope...

Page 1313: ...if the system is in ECT Forced Engine Shutdown Mode Fail safe Mode Conditions for setting the DTC D The ignition is ON D ECT Forced Engine Shutdown Mode is active Fail safe Mode Action Taken When the...

Page 1314: ...d throttle value to the wide open throttle value Closed throttle TP sensor 1 8 10 TP sensor 2 90 92 Wide open throttle TP sensor 1 90 92 TP sensor 2 8 10 Go to Step 8 Go to Step 4 4 1 Ignition OFF 2 D...

Page 1315: ...e 2 With the engine idling monitor MAF Frequency display on the Tech 2 Is the MAF Frequency below the specified value 6 10 g s Go to Step 16 Go to Step 17 14 1 Ignition OFF 2 Disconnect the MAF sensor...

Page 1316: ...p 21 Go to Step 20 20 1 Check the MAP signal circuit between the PCM and MAP ground circuit 2 If the MAP signal circuit is open or shorted repair it as necessary Was the MAP signal circuit open or sho...

Page 1317: ...tatus were detected If missing CQ pulses or multiple CQ pulses or CQ pulse width calculation errors were detected the fail counter will be incremented If the failure counter exceeds the calibration th...

Page 1318: ...rminal to wire connection D Damaged harness Inspect the wiring harness for damage If the harness appears to be OK observe the moving connectors and wiring harnesses related to the sensor A change in t...

Page 1319: ...nnector Was a problem found Verify repair Go to Step 6 5 1 Disconnect the ignition coil Is the action complete Go to Step 6 Go to Step 5 6 Check the ION Sensing harness between the ignition coil and I...

Page 1320: ...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 l...

Page 1321: ...between 26kPa and 100 kPa D Fuel level is more than 10 D Engine speed is between 650rpm and 6500rpm D ION Sensing Module circuit is open or shorted signals on the SEC 1 line Action Taken When the DTC...

Page 1322: ...e Records conditions as noted 4 Using a Tech 2 monitor DTC info for DTC P1311 Does the Tech 2 indicate DTC P1311 failed this ignition Go to Step 3 Refer to Diagnostic Aids 3 1 Ignition OFF 2 Disconnec...

Page 1323: ...n complete Verify repair Go to Step 10 11 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...

Page 1324: ...between 26kPa and 100 kPa D Fuel level is more than 10 D Engine speed is between 650rpm and 6500rpm D ION Sensing Module circuit is open or shorted signals on the SEC 2 line Action Taken When the DTC...

Page 1325: ...ure Records conditions as noted 4 Using a Tech 2 monitor DTC info for DTC P1312 Does the Tech 2 indicate DTC P1312 failed this ignition Go to Step 3 Refer to Diagnostic Aids 3 1 Ignition OFF 2 Disconn...

Page 1326: ...n complete Verify repair Go to Step 10 11 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...

Page 1327: ...culates an air flow value based on idle air control valve position throttle position RPM and barometric pressure D The PCM will store condition which were present when the DTC was set as Freeze Frame...

Page 1328: ...e action complete Go to Step 4 Go to Step 3 4 Check the ION Sensing module harness between the PCM and ION Sensing module circuit at the QC line harness connector Was a problem found Verify repair Go...

Page 1329: ...lete Verify repair Go to Step 10 11 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 la...

Page 1330: ...the fault is detected D The PCM calculates an air flow value based on idle air control valve position throttle position RPM and barometric pressure D The PCM will store condition which were present w...

Page 1331: ...iagnosticAid s 3 1 Ignition OFF 2 Disconnect the ION Sensing module 3 Disconnect the PCM Is the action complete Go to Step 4 Go to Step 3 4 Check the ION Sensing module harness between the PCM and ICS...

Page 1332: ...e action complete Verify repair Go to Step 10 11 Replace the PCM IMPORTANT IMPORTANT The replacement PCM must be programmed Refer to ON Vehicle Service in Power Control Module and Sensors for procedur...

Page 1333: ...illuminate the malfunction indicator lamp MIL after consecutive 2nd trip in which the fault is detected D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in...

Page 1334: ...maged pin or terminal Is the action complete Verify repair 5 1 Remove EGR valve from Engine 2 Inspect EGR valve for any excessive carbon deposit on EGR shaft 3 Inspect for any foreign material inside...

Page 1335: ...2 Go to Step 10 Verify repair 10 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control Module and Sensors for procedures And also refer to...

Page 1336: ...the EVAP purge solenoid ON DTC P1441 will be set Conditions for Setting the DTC D No active ECT sensor IAT sensor MAP sensor vacuum switch or TP sensor DTCs set D BARO reading is above 85 kPa D Engine...

Page 1337: ...was originally stored If not the fault is intermittent 5 Checks for a grounded EVAP purge solenoid driver circuit a faulty EVAP vacuum switch or a leaking EVAP purge solenoid valve DTC P1441 EVAP Sys...

Page 1338: ...er 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...

Page 1339: ...ottle actuation mode is not off D MAF reading ETC estimated air flow is less than 40g s for 250 failres within test 1000 test samples 15 6 m sec Action Taken When the DTC Sets D The PCM will illuminat...

Page 1340: ...tem Check 2 Was the Electric Throttle Control ETC System Check performed Go to Step 3 Go to ETC System Check 3 1 Ignition ON engine OFF 2 Review and record Tech 2 Failure Records data 3 Operate the ve...

Page 1341: ...r 13 Observe the TP angle reading on the Tech 2 while slowly opening the throttle Does the TP angle increase steadily and evenly from the closed throttle value to the wide open throttle value Closed t...

Page 1342: ...1and TP2 sensor 3 If a problem is found repair wiring harness as necessary Was a problem found Verify repair Go to Step 18 18 Replace the TP sensor Is the action complete Verify repair 19 Replace the...

Page 1343: ...test samples 15 6 m sec Action Taken When the DTC Sets D The PCM will illuminate the malfunction indicator lamp MIL the first time the fault is detected D The PCM calculates an air flow value based on...

Page 1344: ...sing a Tech 2 monitor DTC info for DTC P1515 Does the Tech 2 indicate DTC P1515 failed thisignition Go to Step 4 Refer to Diagnostic Aids 4 Observe the TP angle reading on the Tech 2 while slowly open...

Page 1345: ...TP2 signal circuit or 5 volt reference circuit for a poor connection 2 TP1 and TP2 signal circuit or 5 volt reference circuit for high resistance between the PCM and the TP1and TP2 sensor 3 If a prob...

Page 1346: ...ontrol valve position throttle position RPM and barometric pressure D The PCM will store condition which were present when the DTC was set as Freeze Frame and in the Failure Records data Conditions fo...

Page 1347: ...Step 4 Refer to Diagnostic Aids 4 Observe the TP angle reading on the Tech 2 while slowly opening the throttle Does the TP angle increase steadily and evenly from the closed throttle value to the wide...

Page 1348: ...TP2 signal circuit or 5 volt reference circuit for a poor connection 2 TP1 and TP2 signal circuit or 5 volt reference circuit for high resistance between the PCM and the TP1 and TP2 sensor 3 If a pro...

Page 1349: ...longer present D A history DTC P1523 will clear after 40 cosecutive trip cycle during which the warm up cycles have occurred without a fault D DTC P1523 can be cleared using the Tech 2 Clear Info func...

Page 1350: ...k the DC motor harness between the PCM and DC Motor circuit at the DC motor harness connector Was a problem found Verify repair Go to Step 7 6 Replace the DC motor Is the action complete Verify repair...

Page 1351: ...he TP1and TP2 sensor 3 If a problem is found repair wiring harness as necessary Was a problem found Verify repair Go to Step 12 11 Replace the TP sensor Is the action complete Verify repair 12 Replace...

Page 1352: ...fault D DTC P1625 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed Diagnostic Aids Check for the following conditions D P1625 alone stored does not need...

Page 1353: ...Action Taken When the DTC Sets D The PCM will not illuminate the malfunction indicator lamp MIL D The PCM will store condition which were present when the DTC was set as Freeze Frame and in the Failur...

Page 1354: ...HT pin Is the voltage in specified range 11 6 12 7V Go to Step 4 Go to Step 5 4 1 Ignition ON engine not running 2 Using a DVM at the PCM side of the connector check the votage at terminal F57 WHT pin...

Page 1355: ...ction Taken When the DTC Sets D The PCM will not illuminate the malfunction indicator lamp MIL D The PCM will store condition which were present when the DTC was set as Freeze Frame and in the Failure...

Page 1356: ...pin Is the voltage in specified range 11 6 12 7V Go to Step 4 Go to Step 5 4 1 Ignition ON engine not running 2 Using a DVM at the PCM side of the connector check the votage at terminal F57 WHT pin I...

Page 1357: ...will clear after 40 consecutive warm up cycles occur without a fault D DTC P1640 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed Diagnostic Aids Check f...

Page 1358: ...p 7 Go to Step 13 7 1 Leave the PCM connector for the lamp driver circuit disconnected 2 Ignition ON 3 Using a DVM check the voltage at the PCM connector for the affected lamp driver circuit Was the v...

Page 1359: ...4 14 1 Run the engine at idle 2 Check for battery voltage at the fuse for the affected circuit Was battery voltage available at the fuse Go to Step 10 Go to Step 9 15 Replace the PCM IMPORTANT The rep...

Page 1360: ...Inspect harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor terminal to wire connection D Damaged harness Inspect the wiring harnes...

Page 1361: ...7 Go to Step 13 7 1 Leave the PCM connector for the lamp driver circuit disconnected 2 Ignition ON 3 Using a DVM check the voltage at the PCM connector for the affected lamp driver circuit Was the vol...

Page 1362: ...4 1 Run the engine at idle 2 Check for battery voltage at the fuse for the affected circuit Was battery voltage available at the fuse Go to Step 10 Go to Step 9 15 Replace the PCM IMPORTANT The replac...

Page 1363: ...00 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 de...

Page 1364: ...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 re...

Page 1365: ...pair as necessary Was a problem found Verify repair Go to Step 15 15 1 Remove the ignition coils and check the ignition coils for cracks or carbon tracking 2 If a problem is found replace affected coi...

Page 1366: ...em 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 do...

Page 1367: ...lectrodes or heavy deposits Refer to Electronic Ignition System NOTE If spark plugs are gas or oil fouled the cause of the fouling must be determined before replacing the spark plugs 2 If a problem is...

Page 1368: ...exhaust system back pressure Refer to Restricted Exhaust System Check 2 If a problem is found repair as necessary Was a problem found Verify repair Go to Step 20 20 1 Review all diagnostic procedures...

Page 1369: ...strictions Refer to Air Intake System in ON Vehicle Service 2 Replace the air filter element if necessary Was a repair required Verify repair Go to Step 6 6 1 Check for low fuel pressure Refer to Fuel...

Page 1370: ...apsed 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 Rest...

Page 1371: ...ch 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 sw...

Page 1372: ...rness as necessary Was a problem found Go to Step 10 Go to Step 16 15 Replace the ION sensing module Is the action complete Verify repair Go to Step 16 16 1 Check fuel pressure Refer to Chart Fuel Sys...

Page 1373: ...y Was a problem found Verify repair Go to Step 21 21 1 Review all diagnostic procedures within this table 2 If all procedures have been completed and no malfunctions have been found review inspect the...

Page 1374: ...PCM wiring diagrams in Electrical Diagnosis 2 If a problem is found repair as necessary Was a problem found Verify repair Go to Step 6 6 Observe the long term fuel trim on the Tech 2 Is the long term...

Page 1375: ...to Step 14 14 1 Check for fuel in the pressure regulator vacuum hose 2 If fuel is present replace the fuel pressure regulator assembly Refer to Fuel Metering System 3 If a problem is found repair as...

Page 1376: ...iagnosis Was a problem found Verify repair Go to Step 22 22 1 Check for the following engine mechanical items Refer to Engine Mechanical for diagnosis procedures D Low compression D Sticking or leakin...

Page 1377: ...ively heavy loads being carried D Is acceleration too much too often Was a problem found Go to Step 5 Go to Step 6 5 Review the items in Step 4 with the customer and advise as necessary Is the action...

Page 1378: ...found repair as necessary Was a problem found Verify repair Go to Step 14 14 Check for proper calibration of the speedometer Does the speed indicated on the speedometer closely match the vehicle spee...

Page 1379: ...ssary 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 2 If a problem is found repair as necessary Was a pr...

Page 1380: ...st System OK Go to Step 17 16 1 Check items that can cause the engine to run lean Refer to Diagnostic Aids in DTC P0171 Diagnostic Support Make any necessary repairs 2 Perform the exhaust emission tes...

Page 1381: ...ses the symptom Verify repair Go to Step 3 3 Was a visual physical check performed Go to Step 4 Go to Visual Physic al Check 4 1 Check for a short between B and any of the ignition feed circuits 2 If...

Page 1382: ...ugs and check for wet plugs cracks wear improper gap burned electrodes or heavy deposits Refer to Electronic Ignition System NOTE If spark plugs are gas or oil fouled the cause of the fouling must be...

Page 1383: ...repair Go to Step 10 10 1 Check the intake and exhaust manifold s for casting flash Refer to Engine Mechanical 2 If a problem is found repair as necessary Was a problem found Verify repair Go to Step...

Page 1384: ...2 If a problem is found repair as necessary Was a problem found Verify repair Go to Step 6 6 Observe the long term fuel trim on the Tech 2 Is the long term fuel trim significantly in the negative ran...

Page 1385: ...ssure regulator assembly Refer to Fuel Metering System 3 If a problem is found repair as necessary Was a problem found Verify repair Go to Step 15 15 1 Check for proper ignition voltage output with sp...

Page 1386: ...Mechanical for diagnosis procedures D Low compression D Sticking or leaking valves D Worn camshaft lobe s D Camshaft drive belt slipped or stripped D Incorrect valve timing D Worn rocker arms D Broke...

Page 1387: ...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 volt...

Page 1388: ...k the ignition coils for cracks or carbon tracking 2 If a problem is found repair as necessary Was a problem found Verify repair Go to Step 14 14 1 Remove spark plugs and check for wet plugs cracks we...

Page 1389: ...found repair as necessary Was a problem found Verify repair Go to Step 18 18 1 Review all diagnostic procedures within this table 2 If all procedures have been completed and no malfunctions have been...

Page 1390: ...verter Possible faults include D Collapsed pipe D Heat distress D Internal muffler failure Is the action complete Verify repair 4 1 Install the Bank 1 HO2S 2 2 Install the Exhaust Backpressure Tester...

Page 1391: ...erter Possible faults include D Collapsed pipe D Heat distress D Internal muffler failure Is the action complete Verify repair 4 1 Install the Bank 2 HO2S 2 2 Install the Exhaust Back pressure Tester...

Page 1392: ...codes set Customer complains of harsh or soft shift poor performance delayed or no engagement into drive or reverse transmission fluid leak transmission noise or vibration or improper TCC operation Au...

Page 1393: ...TC system check 3 Fuel injector and fuel injector balance test 4 EVAP emission canister purge valve check 5 Ignition system 6 EGR operation MAP Output Check Throttle Linkage EGR System Check A C Clutc...

Page 1394: ...stem diagnosis 4 Fuel injector and fuel injector balance test 5 EGR operation EGR system check Exhaust System Diagnosis Intake Casting Flash Ignition System Check Misfire 1 OBD system check 2 Ignition...

Page 1395: ...emove the CMP sensor from the cylinder head Inspection Procedure 1 Inspect the sensor O ring for cracks or leaks 2 Replace the O ring if it is worn or damaged 3 Lubricate the new O ring with engine oi...

Page 1396: ...h engine oil 4 Install the lubricated O ring Installation Procedure 1 Install the CKP sensor in the engine block 2 Install the CKP sensor mounting bolt Tighten D Tighten the mounting bolt to 9 N m 78...

Page 1397: ...the ECT sensor in the coolant crossover Tighten D Tighten the ECT sensor to 30 N m 22 lb ft 014RY00002 3 Connect the electrical connector 014RY00003 4 Fill the radiator with coolant Refer to Draining...

Page 1398: ...ahead of the right hand catalytic converter TS22912 D Bank 1 sensor 2 is mounted behind the right hand catalytic converter TS22913 D Bank 2 sensor 1 is mounted on the exhaust pipe ahead of the left ha...

Page 1399: ...l connector for grease dirt corrosion and bare wires or worn insulation 2 Inspect the louvered end of the sensor for grease dirt or other contaminations 060RY00017 Installation Procedure IMPORTANT D A...

Page 1400: ...m the intake air duct by using a rocking motion while pulling the sensor Installation Procedure 1 Install the IAT sensor into the grommet in the intake air duct 2 Correct the IAT electrical connector...

Page 1401: ...ct the electrical connector from the MAF sensor TS23740 3 Loosen the clamps which secure the intake air duct and the air cleaner to the MAF sensor 4 Remove the intake air duct from the MAF sensor 5 Re...

Page 1402: ...Remove the bolt securing the MAP sensor to the mounting bracket on the common chamber 4 Remove the MAP sensor from the mounting bracket 055RW002 Installation Procedure 1 Install the MAP sensor in the...

Page 1403: ...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 poss...

Page 1404: ...ntains 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 char...

Page 1405: ...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 Installation Procedure 1 Install the TP sensor on th...

Page 1406: ...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 w...

Page 1407: ...02 Legend 1 Air Cleaner Housing 2 Air Filter Element 3 Air Cleaner Lid Installation Procedure 1 Install the air cleaner housing in the vehicle with the retaining bolts 2 Install the air filter element...

Page 1408: ...ve the two screws from the accelerator pedal assembly 101RY00007 4 Remove the accelerator pedal assembly from the bulkhead Installation Procedure 1 Install the accelerator pedal assembly on the bulkhe...

Page 1409: ...n Procedure 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 cond...

Page 1410: ...r body D The fuel filter body is damaged D The fuel filter is clogged with dirt or sediment Installation Procedure 1 Install the fuel filter in the correct direction 2 Install the bolt on the fuel fil...

Page 1411: ...ten D Tighten the drain plug to 20 N m 14 lb ft TS22907 4 Disconnect the wiring connector from the fuel gauge unit TS23771 5 Remove the fuel gauge unit retaining screws 6 Remove the fuel gauge unit D...

Page 1412: ...lectrical 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 IMPORTANT Fuel...

Page 1413: ...Relief Procedure 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 CAUTI...

Page 1414: ...ce 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 Installation Pr...

Page 1415: ...y 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 sta...

Page 1416: ...re Regulator section 3 Install the common chamber Refer to common chamber in engine Mechanical section 014RW164 4 Connect the vacuum hose on Canister VSV and positive crankcase ventilation hose 5 Conn...

Page 1417: ...s to prevent dust from entering the hoses TS23769 15 Remove the fuel tank retaining bolts on both sides 16 Remove the fuel tank TS23770 Installation Procedure 1 Install the fuel tank D Place the flang...

Page 1418: ...he tank 12 Connect the air breather hose at the tank TS23796 13 Fill the fuel tank with fuel 14 Tighten the fuel filler cap 15 Connect the negative battery cable Throttle Body TB Removal Procedure 1 D...

Page 1419: ...the manifold D Do not leave any scratches in the aluminum casting Installation Procedure 1 Install the TP sensor Refer to Throttle Position TP Sensor section 2 Install the gasket on the common chambe...

Page 1420: ...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...

Page 1421: ...slot on the forward side of the fuel pump relay D The screwdriver blade will release the catch inside D08RW131 4 Pull the relay straight up and out of the fuse and relay box TS23986 Installation Proc...

Page 1422: ...apor connector and the purge hose from the EVAP canister vent solenoid 014RW147 4 Remove the retaining two bolts on the mounting bracket and slide the canister out of mounting bracket 014RW146 Inspect...

Page 1423: ...nect the negative battery cable 2 Slide out the EVAP canister vent solenoid from mounting bracket 014RW149 3 Disconnect the connector and hose 014RW148 Inspection Procedure 1 Check for cracks or leaks...

Page 1424: ...of rot Installation Procedure 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...

Page 1425: ...ge solenoid 014RW137 4 Connect the electrical connector to the EVAP canister purge solenoid 014RW138 Fuel Tank Vent Valve Removal and Installation Procedure Refer to Fuel Pump section Linear Exhaust G...

Page 1426: ...ack to release the hose 2 Pull the PCV valve from the rubber grommet in the right valve cover 014RW097 Inspection Procedure Before inspecting the PCV valve make sure that the hoses are connected prope...

Page 1427: ...ack 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 r...

Page 1428: ...Procedure 1 Splice the wires using splice clips and rosin core solder 2 Wrap each splice to insulate 3 Wrap the splice with mylar and with the drain uninsulated wire 049 4 Tape over the whole bundle...

Page 1429: ...Use splice clips and rosin core solder in order to splice the two wires together 052 2 Cover the splice with tape in order to insulate it from the other wires 053 3 Twist the wires as they were before...

Page 1430: ...minal may be bent or deformed Unlike standard blade terminals these terminals cannot be straightened after they have been improperly bent 071 3 Cut the wire immediately behind the cable seal 072 Insta...

Page 1431: ...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...

Page 1432: ...ate true sequential fuel injection SFI mode of operation If the PCM detects an incorrect CMP signal while the engine is running DTC P0341 will set If the CMP signal is lost while the engine is running...

Page 1433: ...to set The PCM can also detect HO2S response problems If the response time of an HO2S is determined to be too slow the PCM will store a DTC that indicates degraded HO2S performance 060RY00030 Catalys...

Page 1434: ...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 a...

Page 1435: ...through resistances in the PCM which are so high in value that a test light will not light when connected to the circuit In some cases even an ordinary shop voltmeter will not give an accurate readin...

Page 1436: ...o the latest Techline information on reprogramming or flashing procedures Throttle Position TP Sensor The throttle position TP sensor is a potentiometer connected to the throttle shaft on the throttle...

Page 1437: ...ll exists it may be diagnosed in the normal manner Electrostatic Discharge Damage Electronic components used in the PCM are often designed to carry very low voltage Electronic components are susceptib...

Page 1438: ...the fuel injectors de energized as long as the throttle remains above 80 and the engine speed is below 800 RPM If the throttle position becomes less than 80 the PCM again begins to pulse the injectors...

Page 1439: ...s in order to determine the fuel needs of the engine Fuel is delivered under one of several conditions called modes All modes are controlled by the PCM Fuel Pressure Regulator The fuel pressure regula...

Page 1440: ...temperature ECT sensor and the throttle position TP sensor to determine the proper air fuel ratio for starting The PCM controls the amount of fuel delivered in the starting mode by adjusting how long...

Page 1441: ...d at each spark plug The coil at plug module is attached to the engine with two screws It is installed directly to the spark plug by an electrical contact inside a rubber boot A three way connector pr...

Page 1442: ...he 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 s...

Page 1443: ...re 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...

Page 1444: ...g replace it Spark plugs 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...

Page 1445: ...he IAT reading is above 10 C 50 F A continuous purge condition with no purge commanded by the PCM will set a DTC P1441 Poor idle stalling and poor driveability can be caused by D A malfunctioning purg...

Page 1446: ...P sensor However the fuel tank pressure sensor has very different electrical characteristics due to its pressure differential design The sensor measures the difference between the air pressure or vacu...

Page 1447: ...r leak testing 014RW148 D Fuel Level Sensor The fuel level sensor is an important input to the PCM for the enhanced EVAP system diagnostic The PCM needs fuel level information to know the volume of fu...

Page 1448: ...nected or faulty EVAP vent solenoid D Open ignition feed circuit to the EVAP vent or purge solenoid D Damaged EVAP canister D Leaking fuel sender assembly O ring D Leaking fuel tank or fuel filler nec...

Page 1449: ...tion D Above idle speed Too much EGR flow at idle cruise or cold operation may cause any of the following conditions to occur D Engine stalls after a cold start D Engine stalls at idle after decelerat...

Page 1450: ...he 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 flo...

Page 1451: ...r 4 DLC Cable 5 TECH 2 J 34142 B Unpowered Test Light Connector Test Adapter Kit J 35616 A BT 8637 J 26792 BT 7220 1 Spark Tester J 34730 E Port Fuel Injection Diagnostic Kit ILLUSTRATION TOOL NO TOOL...

Page 1452: ...413 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...

Page 1453: ...ion 6F 3 Three Way Catalytic Converter LH 6F 4 Removal 6F 4 Installation 6F 4 Three Way Catalytic Converter RH 6F 5 Removal 6F 5 Installation 6F 5 Exhaust Silencer 6F 6 Exhaust Silencer and Associated...

Page 1454: ...and rubber blocks The installation of exhaust system supports is very important as improperly installed supports can cause annoying vibrations which can be difficult to diagnose Three Way Catalytic C...

Page 1455: ...Sensor Terminal Connector 10 Front Exhaust Pipe RH Removal 1 Disconnect battery ground cable 2 Raise the vehicle and support with suitable safety stands 3 Disconnect O2 sensor harness connector 2 5 7...

Page 1456: ...ifold 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 3 O2 Sensor Harness Connector 4 Front Exhaus...

Page 1457: ...ud nuts 1 from exhaust manifold then remove the exhaust front pipe 5 150RW010 Legend 1 Front Exhaust Pipe Fixing Three Stud Nuts 2 O2 Sensor Harness Connector 3 Front Exhaust Pipe Fixing Bolts and Nut...

Page 1458: ...exhaust pipe from exhaust silencer 4 Remove exhaust silencer fixing bolts 4 then disconnect exhaust silencer from front exhaust pipe 5 5 Remove exhaust silencer mounting nuts from chassis side then r...

Page 1459: ...ery ground cable 2 Raise the vehicle and support with suitable safety stands 3 Remove rear exhaust pipe fixing nuts 3 then disconnect rear exhaust pipe from exhaust silencer 4 Remove mounting rubber 1...

Page 1460: ...6F 8 ENGINE EXHAUST Main Data and Specifications Torque Specifications E06RW022...

Page 1461: ...R NEAR THE SRS COMPONENTS OR THE SRS WIRING REFER TO THE SRS SERVICE INFORMATION FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT PERSONAL INJURY OR OTHERWISE UNNEEDED SRS SYSTEM...

Page 1462: ...essure Switch 5 Oil Filter 6 Safety Valve 7 Oil Pressure Unit 8 Oil Gallery 9 Crankshaft Bearing 10 Crankshaft 11 Connecting Rod Bearing 12 Connecting Rod 13 Piston 14 Oil Gallery Cylinder Head 15 Cam...

Page 1463: ...Assembly 6 Plug 7 Spring 8 Relief Valve 9 Oil Pump Cover 10 Driven Gear 11 Drive Gear 12 Oil Seal 13 O ring 14 Oil Pump Body Disassembly 1 Remove crankshaft timing pulley 2 Remove crankcase with oil p...

Page 1464: ...ced 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...

Page 1465: ...ring 7 5 Install spring 7 6 Install the plug 6 Torque 8 N m 69 lb in 051RS007 7 Install oil pump assembly 5 D Carefully remove any oil from the cylinder body and the pump Apply sealant TB 1207B or equ...

Page 1466: ...oil pipe 3 with O ring 13 Torque 25 N m 18 lb ft 11 Install crankcase with oil pan 2 D Remove oil on crankcase mounting surface and dry the surface D Apply a proper 4 5 mm 0 7 in wide bead of sealant...

Page 1467: ...heel side At this time support the axle with a garage jack and remove axle housing assembly For 4 4 11 Remove starter fixing bolts 12 Remove oil pan fixing bolts 13 Remove oil pan using J 37228 sealer...

Page 1468: ...fter sealant application befor the sealant hardens 013RW003 3 Install oil pan tighten oil pan fixing bolts to the specified torque Torque 25 N m 18 lb ft 3 Install starter and tighten fixing bolts Tor...

Page 1469: ...s member and tighten fixing bolts to the specified torque Torque 78 N m 58 lb ft 013RW007 8 Install radiator under fan shroud 9 Install under cover 10 Install engine oil level dipstick 11 Fill engine...

Page 1470: ...bly cylinder block and take care not to damage mounting surfaces of oil pump and cylinder block Installation 1 Install oil pump assembly D Apply sealant TB 1207B or equivalent to the oil pump mounting...

Page 1471: ...To Oil Filter 5 Install timing pulley on crankshaft Install timing belt D Refer to installation procedure for Timing Belt in this manual 6 Install crankshaft pulley D Refer to install procedure for Cr...

Page 1472: ...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...

Page 1473: ...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...

Page 1474: ...a and Specification General Specification Item Specifications Item 6VE1 Oil capacity 5 3 liters Torque Specifications Crankcase Oil pan Timing belt tensioner Timing pulley timing belt cover Oil pump O...

Page 1475: ...AIR BAG DEPLOYMENT PERSONAL INJURY OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS CAUTION Always use the correct fastener in the proper location When you replace a fastener use ONLY the exact part number fo...

Page 1476: ...n Sensor 2 Accelerator Pedal Assembly Removal 1 Disconnect battery ground cable 2 Disconnect Accelerator position AP sensor 1 connector from Accelerator pedal assembly 3 Remove Accelerator pedal assem...

Page 1477: ...URY OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS CAUTION Always use the correct fastener in the proper location When you replace a fastener use ONLY the exact part number for that application ISUZU will c...

Page 1478: ...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 fro...

Page 1479: ...th Transfer Case Extension Assembly 7A 31 Transmission And Associated Parts 7A 31 Removal 7A 32 Installation 7A 33 Solenoid Main Case Valve Body 7A 38 Removal 7A 38 Installation 7A 38 Solenoid Adapter...

Page 1480: ...embly 7A 72 Inspection And Repair 7A 73 Reassembly 7A 73 Reverse Clutch Piston And Center Support 7A 74 Disassembled View 7A 74 Disassembly 7A 74 Inspection And Repair 7A 75 Reassembly 7A 75 Overrun C...

Page 1481: ...hose 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...

Page 1482: ...7A 4 AUTOMATIC TRANSMISSION 4L30 E Range Reference Chart C07RY00032...

Page 1483: ...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 Diagnosis In...

Page 1484: ...7A 6 AUTOMATIC TRANSMISSION 4L30 E F07RT036 Example of form completed...

Page 1485: ...7A 7 AUTOMATIC TRANSMISSION 4L30 E F07RT037...

Page 1486: ...7A 8 AUTOMATIC TRANSMISSION 4L30 E General Diagnosis Procedure F07RT038...

Page 1487: ...7A 9 AUTOMATIC TRANSMISSION 4L30 E Preliminary Inspection Chart F07RY00001...

Page 1488: ...ng brake firmly 2 Check fluid level with engine running at idle NOTE Be sure that transmission fluid temperature is below 30 C 86 F 3 Move the selector lever through all gear ranges 4 Move the selecto...

Page 1489: ...rom the areas being monitored for use in diagnosis Also listen for and note any unusual noises The following procedure should be used to test drive 4L30 E automatic transmission complaint vehicles 1 T...

Page 1490: ...at 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 trans...

Page 1491: ...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...

Page 1492: ...n roller clutch 516 broken loose Was the problem found Repair or replace Chart 3 No Engine Brake In Any Range Step Action Yes No 1 Check line pressure Refer to Line Pressure Test in this section Was l...

Page 1493: ...05 set Diagnose those DTC s first Use Chart 15b Possible Causes of High Line Pressure in this section Chart 5a Delays In Drive And Reverse NOTE A short delay less than 3 seconds when first engaging dr...

Page 1494: ...lenoid 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 a...

Page 1495: ...stuck in adapter case valve body 401 2 Check for 3 4 accumulator piston 18 stuck in adapter case 20 Was the problem found Repair or replace Chart 9a 3 2 Downshift Complaint Step Action Yes No 1 Check...

Page 1496: ...ng harness damage or short to ground If OK go to 2 2 Check transmission speed sensor connections If OK go to 3 3 Replace transmission speed sensor Was the replacement complete Replace speed sensor Cha...

Page 1497: ...d flush cooler lines Replace converter assembly and O ring on turbine shaft Perform mechanical inspection of other drivetrain components Chart 14 Possible Causes Of Transmission Noise CAUTION Before c...

Page 1498: ...blem found Replace feed limit valve 412 Go to Step 6 6 Check for loose converter bolts 4 5 Was the problem found Tighten converter bolts 4 5 Go to Step 7 7 Check for a stuck pressure regulator valve 2...

Page 1499: ...ck for a stuck feed limit valve 412 Adapter case valve body Was the problem found Replace force motor plunger 412 Go to Step 4 4 Check converter bolts 4 5 Was the problem found Tighten converter bolts...

Page 1500: ...hould be made 1 With the engine running check for external line pressure leaks 2 With the engine off check for oil leaks due to the raised oil level caused by drainback of converter oil into the trans...

Page 1501: ...checks oil pump and control valve pressure regulator valve function It will also detect oil leakage Line Pressure Test Procedure 1 Check the level of the engine coolant the engine oil and the automati...

Page 1502: ...rth Gear 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 2...

Page 1503: ...wnshift Range Throttle opening 1 2 First Gear Second Gear km h mph 2 3 Second Gear Third Gear km h mph 3 4 Third Gear Fourth Gear km h mph D Fully opened 45 51 28 32 104 110 65 68 163 169 101 105 D Dr...

Page 1504: ...4 300 ECCC Apply ECCC Release D range Throttle i 6 Mode 2nd Km h mph 3rd Km h mph 4th Km h mph 2nd Km h mph 3rd Km h mph 4th Km h mph opening 6 Normal 57 63 35 39 42 48 26 30 43 49 27 31 52 58 32 36...

Page 1505: ...is reached 6 Add transmission fluid until it flows out over the overfill screw opening then close the overfill screw 1 Torque 38 N m 28 lb ft NOTE To prevent fluid leaks the overfill screw and oil dr...

Page 1506: ...orward R position side and secure it using a rubber band 3 etc so that the pin comes into contact with the wall of the detent plate 5 Install the shift control rod 1 to the selector lever arm 4 Torque...

Page 1507: ...Remove bracket with mode switch connector from the transmission case 7 Remove mode switch connector 3 from the bracket 4 8 Remove two mode switch bolts and nut then remove mode switch 5 210RW008 Insta...

Page 1508: ...istance 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 conta...

Page 1509: ...Lever 4 4 5 Transfer Protector 4 4 6 Rear Propeller Shaft 7 Front Propeller Shaft 4 4 8 Harness Protector 9 Rear Mount Nut 10 Third Crossmember 11 Left Catalytic Converter Assembly 12 Seat Belt Tensio...

Page 1510: ...ide 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 conne...

Page 1511: ...y from the transmission assembly if necessary Installation 1 Slowly raise transmission jack until front of the transmission is aligned with rear of the engine then install transmission assembly 2 Tigh...

Page 1512: ...8 N m 69 lb in 6 Install front crossmember Torque 78 N m 58 lb ft 7 Install the starter and tighten the bolts to the specified torque Torque 40 N m 30 lb ft 8 Connect transmission harness connectors t...

Page 1513: ...7A 35 AUTOMATIC TRANSMISSION 4L30 E For 4 4 141RW027...

Page 1514: ...onverter assembly and tighten the bolts to the specified torque Exh pipe to exh manifold 67 N m 49 lb ft Exh pipe flange bolt 43 N m 32 lb ft 15 Install left seat belt tension rod Torque 39 N m 29 lb...

Page 1515: ...orque 63 N m 46 lb ft 24 Connect the shift control rod to selector lever assembly 25 Install the transfer protectors and tighten the bolts to the specified torque 4 4 Torque 37 N m 27 lb ft 26 Install...

Page 1516: ...e solenoids by grasping the metal tip Installation 1 Install shift solenoid A shift solenoid B band control solenoid with new gaskets to main case valve body respectively 2 Carefully install spring pi...

Page 1517: ...PWM solenoid with two O rings 210RY001 7 Remove 11 mm bolt retainer and force motor solenoid 210RW009 Installation 1 Install force motor solenoid retainer and 11 mm bolt to adapter case valve body Tig...

Page 1518: ...install main case D Install valve body assembly and manual valve link NOTE Valve must be extended as the short end of manual valve link is connected to the range selector lever Long end of link goes...

Page 1519: ...ical 4 way connector and seal of adapter case Replace if necessary 2 Install gasket transfer plate and gasket 3 Install adapter case valve body and seven 13 mm screws Tighten the screws to the specifi...

Page 1520: ...ift lock cable Refer to Selector Lever in this section 5 Install front console 6 Connect battery ground cable Transmission Oil Temperature Sensor Main Case Removal 1 Raise the vehicle and support it o...

Page 1521: ...ue converter from converter housing 3 Remove three screws and oil seal ring from converter housing 241RW008 Installation 1 Apply clean ATF to the new oil seal ring lip D Install oil seal ring to conve...

Page 1522: ...shaft 3 Remove two 10mm mode switch screws selector lever nut cover and mode switch 3 4 Remove twelve 10mm adapter case oil pan 4 fixing screws adapter oil pan and gasket 5 Disconnect electrical wiri...

Page 1523: ...mission 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 ass...

Page 1524: ...xtension housing assembly 19 and gasket 18 Remove retaining ring 20 NOTE Use extra long needle nose pliers 19 Remove speed wheel 21 20 Remove wheel parking lock with seal ring 22 241RS002 21 Rotate tr...

Page 1525: ...thrust washer 34 and two O ring 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 Remo...

Page 1526: ...uring removal Be aware of pin height Protect machined face of main case 48 Remove parking lock and range selector lever 17 mm nut 57 49 Remove parking lock and range selector lever 56 and actuator ass...

Page 1527: ...ate 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...

Page 1528: ...thrust washer in place 17 Install third clutch and intermediate shaft assembly 13 into the second clutch drum 14 18 Install second and third clutch assemblies into the main case Twist output shaft an...

Page 1529: ...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 2 10 2 20 0 083 0 087 Na...

Page 1530: ...J 38588 guide pins D Install adapter case and center support assembly to main case 242RS004 29 Install thrust washer 26 into adapter case with tangs pointing downwards 30 Preassemble overdrive intern...

Page 1531: ...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 1 91 2 01 0 075 0 079...

Page 1532: ...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 tr...

Page 1533: ...sitioned 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 2307...

Page 1534: ...main oil pan 50 and sixteen 10 mm screws Torque 11 N m 96 lb in 54 Inspect adapter case electrical connector and seal Replace if necessary D Install electrical five pin connector and harness assembly...

Page 1535: ...e in stator g Contamination from engine coolant h Excess end play D Rotate transmission bell housing up Spin converter to insure proper fit 61 Fill transmission through the overfill screw hole of oil...

Page 1536: ...eck 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 conv...

Page 1537: ...ignal Accumulator Piston 22 Sleeve Pin 23 Boost Valve Sleeve 24 Boost Valve 25 Spring Seat 26 Pressure Regulator Valve Spring 27 Spring Seat 28 Pressure Regulator Valve 29 Oil Pump Assembly Disassembl...

Page 1538: ...sembly 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 spr...

Page 1539: ...5 1 2 Accumulator Valve 26 1 2 Accumulator Control Valve 27 Check Ball 28 Main Case Valve Body Disassembly 1 Remove two 11mm bolts from valve body 28 then remove gaskets and transfer plate 1 2 Remove...

Page 1540: ...erations 5 Spring fatigue Reassembly 1 Install 1 2 accumulator control valve 26 1 2 accumulator valve 25 plug 24 and spring pin 23 2 Install band control screen assembly 22 plug 21 and spring pin 20 3...

Page 1541: ...r clutch PWM solenoid 2 2 Remove 11mm bolt and retainer 3 from valve body D Remove force motor solenoid 4 3 Remove retainer 5 plug 6 3 4 accumulator valve 7 and 3 4 accumulator control valve 8 4 Remov...

Page 1542: ...rol valve 8 3 4 accumulator valve 7 plug 6 and retainer 5 4 Install force motor solenoid 4 D Place solenoid terminals pointing towards mating face D Install retainer 3 and bolt Torque 10 N m 87 lb in...

Page 1543: ...d 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 re...

Page 1544: ...ing 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 int...

Page 1545: ...groove D Remove spring seat 2 and springs 3 3 Remove piston assembly 4 from third clutch drum 5 Inspection And Repair Visual check If any damage deformation or wear is found replace the damaged part...

Page 1546: ...at 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 T...

Page 1547: ...r 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...

Page 1548: ...ing Seat 9 Springs 10 Piston Assembly 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...

Page 1549: ...h 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 2 Install twenty two piston springs 9 and spring...

Page 1550: ...ing 4 Piston Assembly Disassembly 1 Install the J 38559 A cover compressor on adapter case D Compress piston cover then remove snap ring 242RS007 2 Install the J 41096 cover remover and J 38584 adapte...

Page 1551: ...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 cove...

Page 1552: ...fer Plate 8 Gasket 9 Restrictor 10 Retainer Plate 11 Plug 12 Spring 13 Overrun Lock Out Valve 14 Retainer Plate 15 Plug 16 Spring 17 Reverse Lock Out Control Valve Disassembly 1 Install the J 23327 co...

Page 1553: ...lve 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 loc...

Page 1554: ...nap Ring 2 Overdrive Carrier Assembly 3 Sun Gear 4 Turbine Shaft 5 Snap Ring 6 Backing Plate 7 Clutch Plates 8 Snap Ring 9 Overrun Roller Clutch Cam 10 Roller Clutch Assembly 11 Overrun Clutch Release...

Page 1555: ...oller clutch cam 9 and roller clutch assembly 10 6 Remove overrun clutch release spring retainer 11 and diaphragm spring 12 7 Remove piston assembly 13 from overrun clutch drum 14 8 Remove turbine sha...

Page 1556: ...e snap ring loosely on spring retainer 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 c...

Page 1557: ...t Noiseless high torque capability Oil used 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 c...

Page 1558: ...7A 80 AUTOMATIC TRANSMISSION 4L30 E Torque Specifications E07RY00013...

Page 1559: ...7A 81 AUTOMATIC TRANSMISSION 4L30 E E07RY003...

Page 1560: ...7A 82 AUTOMATIC TRANSMISSION 4L30 E E07RY001...

Page 1561: ...with J 23075 J 23084 Third clutch piston installer J 23327 Third clutch spring compressor J 23080 A Second clutch piston installer ILLUSTRATION TOOL NO TOOL NAME J 23085 A Selective washer gauging to...

Page 1562: ...to valve body J 25022 Turbine shaft puller Use with J 24773 1 J 23129 Oil seal remover Use with J 23907 and J 38584 J 38557 Oil pump centering tool ILLUSTRATION TOOL NO TOOL NAME J 23082 01 Oil pump...

Page 1563: ...ISSION 4L30 E ILLUSTRATION TOOL NO 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...

Page 1564: ...11 Gasket 12 Washer Thrust Selective 13 Ring Snap 14 Cover 3 4 Accumulator Piston 15 Seal O Ring 3 4 Accumulator 16 Spring 3 4 Accumulator Piston 17 Pin 3 4 Accumulator Piston 18 Piston 3 4 Accumulat...

Page 1565: ...ter Case 72 Gasket Adapter Valve Body 73 Plate Adapter Valve Body Transfer 74 Pan Bottom Main Case 75 Gasket Bottom Pan Main Case 76 Gasket Oil Drain or Overfill Screw 77 Screw Oil Drain or Overfill 7...

Page 1566: ...Signal Accumulator 210 Piston Throttle Signal Accumulator 211 Pin Boost Valve Sleeve 212 Sleeve Boost Valve 213 Valve Boost 214 Seat Spring Pressure Regulator Valve 215 Spring Pressure Regulator Valve...

Page 1567: ...306 Retainer Valve 307 Solenoid Assembly ON OFF N O 308 Valve 2 3 Shift 309 Pin Spring 310 Plug Valve Bore 311 Spring Valve Low Pressure Control 312 Valve Low Pressure Control 317 Ball Check 318 Valv...

Page 1568: ...Motor 405 Plug 3 4 Accumulator 406 Plug and Spring Retainer 407 Valve 3 4 Accumulator 409 Valve 3 4 Accumulator Control 410 Spring Feed Limit Valve 411 Ring Retainer 412 Valve Feed Limit 413 Seal O R...

Page 1569: ...r Assembly Overdrive Clutch 517 Cam Overdrive Roller Clutch 518 Ring Snap Overrun Clutch Hub 519 Gear Overdrive Sun 520 Plate Waved Overrun Clutch 521 Plate Overrun Clutch Steel 522 Plate Assembly Ove...

Page 1570: ...nner 621 Seal 2nd Clutch Piston Outer 622 Piston 2nd Clutch 623 Seat Spring 2nd Clutch 625 Plate Waved 2nd Clutch 626 Plate 2nd Clutch Steel 627 Plate Assembly 2nd Clutch Lined 628 Spacer 2nd Clutch 6...

Page 1571: ...Shaft Input Sun 653 Carrier Assembly Planetary 658 Gear Reaction Sun 659 Drum Reaction Sun 664 Band Assembly Brake 667 Seal Ring Wheel Parking Lock 668 Wheel Parking Lock 672 Wheel Speed 673 Ring Ret...

Page 1572: ...ng assembly 2 Remove end nut and companion flange 2 using the companion flange holder J 8614 11 266RW001 3 Use the universal puller to remove the companion flange and O ring 4 Remove the oil seal from...

Page 1573: ...ten to the specified torque Torque 167 N m 123 lb ft 6 Use the punch J 39209 to stake the end nut at two spots NOTE Be sure to confirm that there is no crack at the staked portion of the end nut 2 aft...

Page 1574: ...7A 96 AUTOMATIC TRANSMISSION 4L30 E Extension Housing Assembly Extension Housing Assembly and Associated Parts 260RY00006 Legend 1 Propeller Shaft 2 Mass 3 Extension Housing Assembly...

Page 1575: ...ensor 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...

Page 1576: ...ng 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 prope...

Page 1577: ...TRANSMISSION 4L30 E Extension Housing Assembly Extension Housing Assembly and Associated Parts 220RY00009 Legend 1 Speedometer Sensor Speedometer Driven Gear and Plate 2 Companion Flange 3 Extension H...

Page 1578: ...on holder J 8614 11 to remove the end nut 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...

Page 1579: ...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 assembl...

Page 1580: ...Extension Housing Assembly 220RY00011 Legend 1 Bearing Snap Ring 2 Front Ball Bearing 3 Extension Shaft 4 Bearing Snap Ring 5 Front Oil Seal 6 Ball 7 Speedometer Drive Gear 8 Rear Ball Bearing 9 Air B...

Page 1581: ...ss and bearing remover J 22912 01 220RY00007 9 Remove air breather pipe collar 9 from the extension housing assembly Reassembly 1 Install air breather pipe collar 9 to the extension housing assembly C...

Page 1582: ...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 bear...

Page 1583: ...7A 105 AUTOMATIC TRANSMISSION 4L30 E Main Data and Specifications General Specifications Oil capacity 0 185 lit 0 195 U S quart Type of lubricant ATF DEXRON III Torque Specifications 220RY00012...

Page 1584: ...7A 106 AUTOMATIC TRANSMISSION 4L30 E Special Tools ILLUSTRATION PART NO PART NAME J 22912 01 Bearing remover installer J 39209 Punch end nut J 39208 Rear oil seal installer J 8614 11 Flange holder...

Page 1585: ...ntification 7A1 23 Isuzu Trooper 7A1 23 Diagnostic Trouble Code DTC Identification 7A1 24 DTC P0218 Transmission Fluid Over Temperature 7A1 25 DTC P0705 Transmission Range Switch Mode Switch Illegal P...

Page 1586: ...l Description The 4L30 E is a 4 speed fully automatic transmission It uses a microcomputer as a control unit to judge running conditions including throttle opening rate and vehicle speed then it sets...

Page 1587: ...TRANSMISSION CONTROL SYSTEM 4L30 E 7A1 3 Electronic Control Diagram C07RY00034...

Page 1588: ...7A1 4 TRANSMISSION CONTROL SYSTEM 4L30 E Powertrain Control Module PCM C07RY002...

Page 1589: ...TRANSMISSION CONTROL SYSTEM 4L30 E 7A1 5 Control System Diagram C07RY00033...

Page 1590: ...ion Fail Safe Mechanism If there is a problem in the transmission system the PCM will go into a backup mode The vehicle can still be driven but the driver must use the select lever to shift gears Torq...

Page 1591: ...TRANSMISSION CONTROL SYSTEM 4L30 E 7A1 7 Shift Mode Control F07RX001...

Page 1592: ...7A1 8 TRANSMISSION CONTROL SYSTEM 4L30 E Gear Shift Control F07RT034...

Page 1593: ...tion 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 a...

Page 1594: ...r has been switched on or not and feeds the information to PCM Winter switch fixed to front console Senses whether the driver has selected the winter mode and feeds the information to PCM Cruise contr...

Page 1595: ...agrams 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 G...

Page 1596: ...TOD or 6 WO TOD of connector I 9 is shorted to ground 3 Verify if the PCM connector J2 RED terminal 46 is shorted to ground 4 Verify that the instrument panel terminal 15 WO TOD or 26 W TOD of connect...

Page 1597: ...I Connection In order to access OBD II Powertrain Control Module PCM data use of the Tech 2 scan tool kit 7000086 is required 1 The electronic diagnosis equipment is composed of 1 Tech 2 hand held sca...

Page 1598: ...E 16 19 Adapter 4 DLC Cable 5 Tech 2 D Before operating the Isuzu PCMCIA card with the Tech 2 the following steps must be performed 1 The Isuzu 2000 System PCMCIA card 1 inserts into the Tech 2 5 2 Co...

Page 1599: ...ignition turns on 7 Verify the Tech 2 power up display 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 8 The power up screen i...

Page 1600: ...s 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...

Page 1601: ...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 disp...

Page 1602: ...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...

Page 1603: ...AE J1850 recommended practice for serial data Serial Data refers to information which is transferred in a linear fashion over a single line one bit at a time A Data Bus is an electronic pathway throug...

Page 1604: ...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 da...

Page 1605: ...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...

Page 1606: ...ition or while walking some distance Information On PCM 1 The Powertrain Control Module PCM is located in the center console and is the control center of the electronic transmission control system 2 T...

Page 1607: ...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 a...

Page 1608: ...Clutch TCC System Stuck ON B ON Flash P0748 Pressure Control Solenoid PCS Force Motor Circuit Electrical C Flash P0751 Shift Solenoid A Performance Stuck OFF B ON Flash P0752 Shift Solenoid A Perform...

Page 1609: ...e vehicle has achieved 40 warm up cycles without a failure reported D The PCM will cancel the DTC default actions when the fault no longer exists and the ignition is cycled off long enough to power do...

Page 1610: ...function is used 3 Record the DTC Failure Records Is the TFT sensor signal voltage less than 0 33 volts Go to Step 4 Go to Diagnostic Aids 4 1 Turn the ignition off 2 Disconnect the transmission 16 w...

Page 1611: ...positions met for 5 seconds Action Taken When The DTC Sets D Default to D position D Inhibit torque management D Maximum line pressure D Turn force motor OFF D The PCM will not illuminate the Malfunc...

Page 1612: ...l to the manual valve actually selected 6 This test checks for continuity between each selected range switch connector terminals Range Switch Logic Table Range Range Switch Pin g Position A B C P G Pa...

Page 1613: ...ge 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 pro...

Page 1614: ...his DTC detects an invalid state of the range switch or the range switch circuit by deciphering the range switch inputs This is a type D DTC Conditions For Setting The DTC This DTC will set if any of...

Page 1615: ...ossible intermittent short or open condition move the wiring harness while observing test equipment for a change D Refer to the Range Switch Logic Table or Functional Test Procedure for further inform...

Page 1616: ...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 probl...

Page 1617: ...eater than 120 rpm for greater than 410 seconds since engine startup cumulative timer D Battery voltage is between 10 and 16 volts All of the above is true and either of the following occurs D If the...

Page 1618: ...Condition in Automatic Transmission 4L30 E section 3 1 Install the scan tool 2 With the engine off turn the ignition switch to the on position NOTE Before clearing DTCs use the scan tool in order to...

Page 1619: ...tep 10 9 Replace the automatic transmission wiring harness assembly Is the replacement complete Go to Step 12 10 Replace TFT Sensor Refer to Transmission Oil Temperature Sensor Main Case in Automatic...

Page 1620: ...ons For Clearing The DTC D The DTC can be cleared from the PCM history by using a scan tool D The DTC will be cleared from history when the vehicle has achieved 40 warmup cycles without a failure repo...

Page 1621: ...reference as data will be lost when the Clear Info function is used 3 Record the DTC Freeze Frame and Failure Records Does the scan tool display a TFT sensor signal voltage less than 0 4 volts Go to...

Page 1622: ...ground Was a problem found Go to Step 13 Go to Step 11 11 Check the PCM for faulty connections Was a problem found Go to Step 13 Go to Step 12 12 Replace the PCM Refer to Powertrain Control Module PC...

Page 1623: ...istory by using a scan tool D The DTC will be cleared from history when the vehicle has achieved 40 warmup cycles without a failure reported D The PCM will cancel the DTC default actions when the faul...

Page 1624: ...ch on NOTE Before clearing DTC s use the scan tool to record Freeze Frame and Failure Records for reference as data will be lost when the Clear Info function is used 3 Record the DTC Freeze Frame and...

Page 1625: ...matic Transmission 4L30 E section Is the replacement complete Go to Step 14 10 Check circuit RED WHT for an open or short to B Was a problem found Go to Step 14 Go to Step 11 11 Check circuit RED BLK...

Page 1626: ...events occur seven consecutive times D The vehicle speed is less than 8 km h 5 mph D then the vehicle speed is 8 32 km h 5 20 mph for 4 seconds D then the vehicle speed is greater than 32 km h 20 mph...

Page 1627: ...amp 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 o...

Page 1628: ...to verify your repair perform the following procedure 1 Select DTC 2 Select Clear Info 3 With the engine off turn the ignition switch to the on position 4 Do not depress the brake pedal 5 Verify that...

Page 1629: ...illuminate refer to DTC type definition type B Conditions For Clearing The MIL DTC D The PCM will turn off the MIL and CHECK TRANS Lamp after three consecutive ignition cycles without a failure repor...

Page 1630: ...tween 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 gre...

Page 1631: ...uit RED Is the repair complete Go to Step 17 16 Replace the PCM Refer to Powertrain Control Module PCM in automatic Transmission 4L30 E section Is the replacement complete Go to Step 17 17 1 After the...

Page 1632: ...D Maximum line pressure D Inhibit TCC engagement D For lamp illumination refer to DTC type definition type B Conditions For Clearing The MIL DTC D The PCM will turn off the MIL and CHECK TRANS Lamp a...

Page 1633: ...between 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 g...

Page 1634: ...rcuit RED Is the repair complete Go to Step 17 16 Replace the PCM Refer to Powertrain Control Module PCM in Automatic Transmission 4L30 E section Is the replacement complete Go to Step 17 17 1 After t...

Page 1635: ...cur seven consecutive times D The vehicle speed is greater than 32 km h 20 mph for 4 seconds D then the vehicle speed is between 8 32 km h 5 20 mph for 4 seconds D then the vehicle speed is less than...

Page 1636: ...re 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 t...

Page 1637: ...is is a type C DTC Conditions For Setting The DTC D No Output Speed Sensor DTC s P0722 P0723 D Not in Park Neutral or Reverse D Engine speed is greater than 3 500 rpm D 3 seconds since upshift D No Tr...

Page 1638: ...e you sent here from the On Board Diagnostic OBD System Check Go to Step 2 Go to OBD System Check Refer to Driveability and Emission in Engine section 2 Visually inspect the transmission cooling syste...

Page 1639: ...ical Hydraulic Diagnosis Symptoms Index in Automatic Transmission 4L30 E section Was condition found and corrected Go to Step 7 7 1 After the repair is complete use the scan tool to select DTC then Cl...

Page 1640: ...noid DTC P1860 D TP angle is greater than 20 D Engine speed is greater than 500 rpm and less than 3 000 rpm D Engine vacuum is between 0 and 70 kPa D Commanded gear is not 1st D Gear range is D4 D TCC...

Page 1641: ...fo function is used 3 Record the DTC Freeze Frame and Failure Records 4 Using the scan tool verify the TP Sensor operation Are the TP Sensor values within 0 6 5 0 volts Go to Step 3 Go to Diagnostic A...

Page 1642: ...tor OFF Durability Conditions For Clearing The DTC CHECK TRANS Lamp D The PCM will turn off the CHECK TRANS Lamp after three consecutive ignition cycles without a failure reported D The DTC can be cle...

Page 1643: ...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...

Page 1644: ...conditions 1 2 occur two consecutive times Condition 1 D 2nd gear is commanded for 1 sec D 40 Engine Torque 400 N m D Throttle positon 10 D 800 TCC slip 4000 rpm D Speed ratio 0 6 D 2 75 Modeled Rati...

Page 1645: ...nsmission range D1 D2 D3 D4 N R and P Does each selected transmission range match the TR Switch on the scan tool Go to Step 3 Go to Range Switch Logic Table 3 1 While the engine is operating raise the...

Page 1646: ...cur two consecutive times Condition 1 D 1st gear is commanded for 1 sec D 40 Engine Torque 400 N m D Throttle positon 10 D 8000 TCC slip 8000 rpm D Transmission out speed 375 rpm D Speed ratio 0 3 D 1...

Page 1647: ...smission range D1 D2 D3 D4 N R and P Does each selected transmission range match the TR Switch on the scan tool Go to Step 3 Go to Range Switch Logic Table 3 1 While the engine is operating raise the...

Page 1648: ...oltage is between 10 and 16 volts D The PCM commands the solenoid on and the voltage remains high B or the PCM commands the solenoid off and the voltage remains low zero volts D All conditions met for...

Page 1649: ...learing 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 Wer...

Page 1650: ...d Go to Step 19 14 The wiring harness between PCM connector J1 or J2 and transmission 16 way connector H 56 is open or poor connection Was a problem found and corrected Go to Step 19 15 The wiring har...

Page 1651: ...two consecutive times Condition 1 D 1st gear is commanded for 1 sec D 40 Engine Torque 400 N m D Throttle position 10 D 2300 TCC slip 200 rpm D Transmission out speed 400 rpm D Speed ratio 0 3 D 0 60...

Page 1652: ...each selected transmission range match the TR Switch on the scan tool Go to Step 3 Go to Range Switch Logic Table 3 1 While the engine is operating raise the drive wheels 2 With the transmission in D4...

Page 1653: ...ccur two consecutive times Condition 1 D 3rd gear is commanded for 1 sec D 40 Engine Torque 400 N m D Throttle positon 10 D 8000 TCC slip 8000 rpm D Transmission out speed 375 rpm D Speed ratio 0 6 D...

Page 1654: ...ach selected transmission range match the TR Switch on the scan tool Go to Step 3 Go to Range Switch Logic Table 3 1 While the engine is operating raise the drive wheels 2 With the transmission in D4...

Page 1655: ...and 16 volts D The PCM commands the solenoid on and the voltage remains high B or the PCM commands the solenoid off and the voltage remains low zero volts D All conditions met for 0 84 1 0 seconds Ac...

Page 1656: ...will be lost when the Clear Info function is used 3 Record the DTC Freeze Frame and Failure Records Were DTCs P0753 P0758 P1860 set Go to Step 4 Go to Step 3 3 1 The engine on 2 Apply brake pedal and...

Page 1657: ...sion 16 way connector H 56 Was a problem found and corrected Go to Step 26 Go to Step 14 14 1 Connect the J1 BLUE and J2 RED PCM connectors to the PCM 2 Turn the ignition on the engine on 3 Repeat Ste...

Page 1658: ...rminal H56 12 and transmission main case connector terminal M7 6 A or between H56 11 and M7 2 D is open Was a problem found and corrected Go to Step 26 24 The internal wiring harness from the shift so...

Page 1659: ...ying a voltage to one side the High side and a ground to the other side Low side D The High Side Driver HSD is a circuit of the PCM that acts as a switch between the solenoids and the supply voltage T...

Page 1660: ...rn the ignition switch on NOTE Before clearing DTC s use the scan tool to record Freeze Frame and Failure Records for reference as data will be lost when the Clear Info function is used 3 Record the D...

Page 1661: ...terminal H56 9 and ground Is there a continuity Go to Step 16 Go to Step 22 15 1 Disconnect the transmission main case connector M 7 2 Using the J39200 DVOM measure the resistance between terminals M...

Page 1662: ...orrected Go to Step 27 25 The wiring harness between the transmission 16 way connector terminal H56 9 and the transmission main case connector terminal M7 7 B is open Was a problem found and corrected...

Page 1663: ...n D The PCM commands the solenoid on and the voltage remains low zero volts D The PCM commands the solenoid off and the voltage remains high B D All conditions met for 0 875 1 25 seconds Action Taken...

Page 1664: ...10 0 5 ohms at 20 C 68 F Go to Step 7 Go to Step 8 6 The wiring harness between PCM connector terminal J2 51 and transmission adapter case connector terminal M6 1 A is shorted to voltage Was a proble...

Page 1665: ...problem found and corrected Go to Step 21 17 The wiring harness between transmission 4 way connector terminal H54 2 and adapter case terminal M6 1 A is open Was a problem found and corrected Go to St...

Page 1666: ...is between 250 rpm and 800 rpm for 3 times 7 seconds D Vehicle speed is between 25 km h 15 mph and 225 km h 158 mph D Speed ratio is between 0 6 and 0 95 D ECCC is ON D Low 0 8 TCC Capacity hi 0 99 fo...

Page 1667: ...e you sent here from the Powertrain On Board Diagnostic OBD System Check Go to Step 2 Go to OBD System Check Refer to Driveability and Emissions in Engine section 2 1 Install the scan tool 2 With the...

Page 1668: ...7A1 84 TRANSMISSION CONTROL SYSTEM 4L30 E Connector List No Connector face No Connector face B 13 H 41 E 53 J2 H 53 E 54 J1 H 54 H 8 H 55 H 10 H 56 H 11 H 57 H 24 I 9 H 25 M 6 H 32 M 7...

Page 1669: ...TRANSMISSION CONTROL SYSTEM 4L30 E 7A1 85 No Connector face No Connector face M 15 M 25...

Page 1670: ...INFORMATION FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT PERSONAL INJURY OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS CAUTION Always use the correct fastener in the proper locati...

Page 1671: ...7B 2 MANUAL TRANSMISSION General Description A07RW023...

Page 1672: ...n Replace Shift arm and synchronizer sleeve groove worn Replace worn parts Thrust washer collar and or gear thrust faces worn Mainshaft and counter shaft thrust play Replace worn parts Synchronizer pa...

Page 1673: ...e front console assembly 5 Remove the grommet assembly 6 Remove the transmission control lever and transfer control lever 235RX001 7 Remove transfer protector 8 Remove the rear propeller shaft NOTE Ap...

Page 1674: ...speed sensor and 2WD 4WD actuator harness connectors 225RW007 12 Disconnect the 4WD indicator harness connector 220RW006 13 Remove two transmission harness clamps from the transmission case and bracke...

Page 1675: ...7B 6 MANUAL TRANSMISSION 141RW024 15 Remove the heat protector 225RW006 16 Remove the slave cylinder 206RW002...

Page 1676: ...lts 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 2...

Page 1677: ...e transmission disassembly required Refer to Transfer Case in Drive Line Axle section Installation 1 Apply a thin coat of molybdenum disulfide grease to the top gear shaft spline 2 Slowly operate the...

Page 1678: ...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...

Page 1679: ...d crossmember to the frame and tighten the fixing bolts specified torque Torque 50 N m 37 lb ft 12 Tighten the engine rear mount nuts specified torque Torque 50 N m 37 lb ft 13 Remove the transmission...

Page 1680: ...UAL TRANSMISSION 7B 11 141RW024 19 Install bracket and two transmission harness clamps to the transmission case 220RS028 20 Connect the speedometer sensor and 2WD 4WD actuator harness connector 225RW0...

Page 1681: ...Install the rear propeller shaft and tighten the fixing bolts and nuts specified torque Torque 63 N m 46 lb ft 24 Install transfer protector and tighten the fixing bolts specified torque Torque 37 N m...

Page 1682: ...4 2nd Gear 15 Synchronizer Assembly 16 Clutch Hub No 1 Assembly 17 Snap Ring 18 Synchronizer Assembly 19 1st Gear 20 1st Gear Bearing Spacer 21 1st Gear Needle Roller Bearing 22 1st Gear Thrust Washer...

Page 1683: ...Gear Spline Piece 44 Snap Ring 226RW181 Legend 1 3rd 4th Shift Arm 2 1st 2nd Shift Arm 3 3rd 4th Shift Rod 4 Ball 5 Spring 6 1st 2nd Shift Rod 7 Snap Ring 8 Interlock Pin 9 Reverse Shift Arm Bracket 1...

Page 1684: ...3 Front Cover 4 Snap Ring 5 Snap Ring 6 1st and 2nd Switch 7 Drain Plug 8 Backup Light Switch 9 Plug 10 Transmission Case 11 Filler Plug 12 Oil Receiver Pipe 13 Reverse Restrict Pin 14 Gear Control Ro...

Page 1685: ...move 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 220RW086 3 Re...

Page 1686: ...lutch housing 220RW008 5 Remove gear control box and gasket 1 Remove the 6 bolts gear control box and gasket 230RW001 6 Remove transfer adapter 1 Using a hexagon wrench remove the plug 1 220RW010 2 Us...

Page 1687: ...gear control rod 220RW098 4 Remove the 10 bolts and clamp 220RW016 5 Using a plastic hammer tap the transfer adapter NOTE D Be careful not to lose the pin D Cover the mainshaft splines with adhesive t...

Page 1688: ...ammer drive out the slotted spring pin Remove the reverse restrict pin 220RW012 3 Remove the oil receiver pipe 220RW011 4 Remove the oil seal 5 Using socket hexagon wrench remove the plug 220RW014 8 R...

Page 1689: ...he front cover oil seal 1 Mount the front cover through the aluminum plate in a vise 2 Using screwdriver remove oil seal 1 220RW019 10 Remove the transmission case 1 Using a snap ring expander remove...

Page 1690: ...m plate in a vise 226RW005 12 Remove the slotted spring pin 1 Using a pin punch and hammer drive out the pin from the arm 226RW025 13 Remove the shift arm set bolt 1 Remove the 2 bolts from the shift...

Page 1691: ...ove the hub sleeve No 3 block ring set counter 5th gear bearing and 5th shift arm 220RW101 4 Remove the synchronizer pull ring synchronizer cone ring and synchronizer outer ring from hub sleeve No 3 2...

Page 1692: ...om counter gear shaft 226RW018 16 Remove the bearing plate 1 Remove the 4 bolts and bearing retainer 226RW016 17 Remove the reverse idle gear 1 Pull out the shaft foward the rear and remove the revers...

Page 1693: ...t to drop the counter gear when removing the bearing 226RW036 3 Remove the counter gear from intermediate plate 226RW030 19 Disassemble the counter gear shaft assembly 1 Using snap ring pliers remove...

Page 1694: ...e top gear shaft from mainshaft NOTE Don t fall needle roller bearing 226RW029 2 Remove the 4th block ring and roller bearing 226RW031 21 Disassemble the top gear shaft assembly 1 Check for wear or da...

Page 1695: ...ring 226RW069 22 Remove the mainshaft 1 Remove mainshaft bearing snap ring 226RW035 2 Using a plastic hammer tap the 5th reverse shift rod at the reverse shift side 226RW034 3 Remove the intermediate...

Page 1696: ...gear thrust clearance Gear Standard Clearanse 1st 0 15 0 45 mm 0 0059 0 0177 in 2nd 0 10 0 25 mm 0 0039 0 0098 in 3rd 0 10 0 25 mm 0 0039 0 0098 in 226RW070 2 Inspect each gear radial clearance 1 Usi...

Page 1697: ...ng parts from mainshaft 1 Synchronizer assembly 1 2 1st gear thrust washer pin 3 3 1st gear needle roller bearing 4 4 1st gear bearing spacer 2 226RW146 6 Using 2 screwdrivers and hammer tap out snap...

Page 1698: ...nsert spring with a screwdriver 226RW075 10 Remove the snap ring NOTE Don t damage the bearing surface 226RW076 11 Using a press remove following parts 1 Clutch hub No 2 assembly 1 2 3rd block ring 2...

Page 1699: ...he aluminum plate in a vise 2 Using a plastic hammer tap the 5th shift rod on the neutral 226RW052 3 Using a torx socket wrench T40 remove the 4 plugs 226RW050 4 Using a magnetic finger remove 3 sprin...

Page 1700: ...t the 3rd 4th shift rod at the rear 226RW047 7 Using a magnetic finger remove the interlock pin and straight pin 226RW043 8 Pull out the 1st 2nd shift rod at the rear 226RW045 9 Using a magnetic finge...

Page 1701: ...the 5th reverse shift rod at the front 226RW040 12 Using a magnetic finger remove the interlock pin from the intermediate plate Remove the ball from the reverse shift arm No 1 226RW039 13 Pull out at...

Page 1702: ...remove at the rear 226RW055 15 Using a magnetic finger remove the ball and spring from reverse shift arm No 1 226RW056 16 Remove the reverse shift arm No 2 E ring Remove the reverse shift arm No 2 fr...

Page 1703: ...th gear radial clearance Standard 0 015 0 068 mm 0 00059 0 00268 in 226RW183 4 Using a inside dial indicator measure the gear inside diameter Standard 38 015 38 040 mm 1 49665 1 49763 in 226RW085 2 5t...

Page 1704: ...ise 2 Using a dial indicator measure the reverse idle gear radial clearance Standard 0 040 0 082 mm 0 0016 0 0032 in 226RW083 3 If the clearance exceeds the maximum measure the gear inside diameter an...

Page 1705: ...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...

Page 1706: ...k replace the block ring 226RW060 7 Install the needle roller bearing 2 Reassemble the mainshaft assembly NOTE Apply all parts with gear oil before installing them 3 Inspect block ring 1 Using a thick...

Page 1707: ...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 C...

Page 1708: ...984 38 000 mm 1 4954 1 4961 in B 46 984 47 000 mm 1 8498 1 8504 in C 38 979 38 995 mm 1 5346 1 5352 in 226RW078 2 Using a micrometer measure the mainshaft flange thickness Standard 5 0 mm 0 197 in 226...

Page 1709: ...sert springs so that their end gaps are not in line 226RW099 3 Using installer J 42797 and a press install the clutch hub No 2 and hub sleeve No 2 to the mainshaft NOTE D Align the block ring slots wi...

Page 1710: ...a thickness gauge inspect the 3rd gear thrust clearance Standard 0 10 0 25mm 0 004 0 010 in 226RW103 10 Install the 2nd gear 1 Install the synchronizer ring set NO 1 to the 2nd gear NOTE Align the nai...

Page 1711: ...tion as shown 226RW109 3 Using installer J 42798 and a press install the hub No 1 by retaining the reverse gear NOTE D Align the projection of inner ring with hub No 1 slots D Check that the gear rota...

Page 1712: ...0 10 0 25mm 0 004 0 010 in 226RW113 12 Install the 1st gear 1 Install the following parts 1 1st gear bearing spacer 4 2 1st gear needle roller bearing 3 3 Synchronizer assembly 2 4 1st gear 1 NOTE D A...

Page 1713: ...42799 and a press install the 5th gear 2 Select a snap ring that will allow minimum axial play Mark Thickness C 2 75 2 80 mm 0 108 0 110 in D 2 80 2 85 mm 0 110 0 112 in E 2 85 2 90 mm 0 112 0 114 in...

Page 1714: ...71 16 Install the counter gear shaft 1 Check the new counter front bearing inner race and the side race as shown 2 Using installer J 42800 and a press install the counter gear shaft front bearing 226R...

Page 1715: ...5 mm 0 46 0 02 in 2 Apply grease to the seal lip 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...

Page 1716: ...threads THREE BOND 1344 or equivalent 8 Using a torx socket wrench T40 install and torque the plug Torque 18 5 N m 13 5 lb ft 220RW013 9 Using hexagon wrench install and torque the plug Torque 37 N m...

Page 1717: ...se shift arm No 2 to the reverse shift arm No 1 Using screwdriver and a hammer install the new E ring 226RW138 4 Install reverse shift arm No 2 to the reverse shift arm bracket 226RW012 20 Install the...

Page 1718: ...se 5th shift rod 1 Install the reverse shift arm No 1 lock ball to the reverse shift arm No 1 2 Install the interlock pin to the intermediate plate 226RW039 3 Put in the reverse 5th shift rod from the...

Page 1719: ...e interlock pin to the intermediate plate 226RW042 2 Put in the 1st 2nd shift rod from the rear 226RW044 23 Install 3rd 4th shift rod 1 Install the straight pin and interlock pin to the intermediate p...

Page 1720: ...s to the intermediate plate 226RW049 3 Clean up the plug hole 4 Apply sealant to the plug threads sealant three bond 1344 or equivalent 5 Using a torx socket wrench T40 install and torque the 4 plugs...

Page 1721: ...10 3 Using a plastic hammer tap the intermediate plate and install the mainshaft Through the shift arm No 1 and No 2 to the shift rod 226RW009 4 Using a snap ring expander install the snap ring 226RW0...

Page 1722: ...eck that the gear rotates smoothly 226RW006 27 Install the counter gear shaft 1 Temporarily install the counter gear shaft to the intermediate plate 226RW028 2 Using installer J 42796 and a hammer dri...

Page 1723: ...erse idle gear shaft Torque 12 5 N m 109 lb in 226RW016 30 Install the 5th gear thrust washer 1 Install the 5th gear thrust washer pin to the counter gear shaft 2 Install the 5th gear thrust washer to...

Page 1724: ...121 3 Turn to 30 degree the reverse synchronizer pull ring 226RW080 4 Install the hub sleeve No 3 and reverse block ring set to the counter 5th gear NOTE Check the hub sleeve No 3 direction as shown R...

Page 1725: ...rojection of the cone ring to the holes of the 5th gear spline piece D Check that the gear rotates smoothly 226RW013 8 Using thickness gauge measure the counter 5th gear thrust clearance Standard 0 10...

Page 1726: ...Torque 19 5 N m 14 lb ft 226RW023 33 Install the shift arm slotted pin 1 Using a pin punch and a hammer drive in the slotted pin to the shift arm 226RW025 34 Install the transmission case 1 Clean up...

Page 1727: ...haft bearing snap ring 2 226RW004 6 Turn over the transmission 35 Install the front cover 1 Clean up the fitting surface 2 Apply recommended liquid gasket THREE BOND 1281 or equivalent as shown NOTE D...

Page 1728: ...026 3 Using a plastic hammer tap the transfer adapter and attach it to the intermediate plate 220RW034 4 Using 10 bolts install the transfer adapter Torque 37 N m 27 lb ft NOTE D Tighten the all bolts...

Page 1729: ...D 1344 or equivalent to the plug 1 thread 4 Using hexagon wrench install and torque the plug 1 Torque 18 N m 13 lb ft 220RW010 5 Clean up the bolts and bolt hole 6 Using 6 bolts install the gear contr...

Page 1730: ...ease 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...

Page 1731: ...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 q...

Page 1732: ...MANUAL TRANSMISSION 7B 63 E07RW030...

Page 1733: ...ounter gear shaft center bearing installer J 42797 Clutch hub No 2 installer J 42798 Clutch hub No 1 installer ILLUSTRATION TOOL NO TOOL NAME J 42799 Installer J 42800 Counter gear shaft front bearing...

Page 1734: ...MANUAL TRANSMISSION 7B 65 ILLUSTRATION TOOL NO TOOL NAME J 22912 01 Bearing separator...

Page 1735: ...OR THE SRS WIRING WHEN YOU ARE PERFOMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING REFER TO THE SRS SERVICE INFORMATION FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLO...

Page 1736: ...H General Description Clutch A07RW046 For 6VE1 3 5L engine model the pull type clutch is employed The pull type clutch is disengaged by pulling the release lever release bearing to disengage the press...

Page 1737: ...CLUTCH 7C 3 Master Cylinder A07RW007 Slave Cylinder A07RS005...

Page 1738: ...7C 4 CLUTCH Pressure Plate Assembly A07RS006...

Page 1739: ...CLUTCH 7C 5 Driven Plate Assembly A07RS007...

Page 1740: ...ster cylinder and slave cylinder seals worn Replace seals Chattering Engine mounts loose or damaged Tighten or replace Driven plate facing warped Replace driven plate Surface of facing hardened Replac...

Page 1741: ...e Assembly 4 Transmission Assembly 5 Front Cover 6 Shift Fork 7 Release Bearing Removal 1 Remove transmission assembly refer to MANUAL TRANSMISSION of Section 7B for Removal AND INSTALLATION procedure...

Page 1742: ...flywheel assembly and crankshaft bearing do not remove except for replacement 11 Use the remover J 5822 and sliding hammer J 23907 to remove the crankshaft bearing 015RW050 Inspection and Repair Make...

Page 1743: ...stance B becomes 12 mm 0 472 in 4 Note the pressure gauge reading 5 If the measured value is less than the specified limit the pressure plate assembly must be replaced Clutch Set Force Standard 7208 N...

Page 1744: ...ub 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...

Page 1745: ...0 2 mm 0 008 in Release Bearing 201RS011 1 Visually check the release bearing for excessive play noise and breakage 2 If any of these conditions are discovered the release bearing must be replaced 3 W...

Page 1746: ...and driver handle J 8092 to install the crankshaft bearing then clean and lubricate with grease 015RS046 2 Install new flywheel fixing bolts in the order illustrated and tighten them to the specified...

Page 1747: ...areas shown in illustration 201RW012 9 Install the release bearing in the proper direction NOTE Ensure release bearing is properly positioned during installation as shown in illustration 201RW020 10 I...

Page 1748: ...mbly and tighten the bolts holding the pressure plate assembly in the order shown in illustration Torque 18 N m 13 lb ft 201RS017 12 Remove the aligner NOTE Do not strike the aligner with a hammer to...

Page 1749: ...ly and Heat Protector Removal 1 Remove pin and jaw joint pin 2 Remove pedal assembly and switch 3 Remove oil line pipe 4 Remove slave cylinder assembly and heat protector 5 Remove master cylinder asse...

Page 1750: ...switch out until there is a gap between the switch plunger and clutch pedal 203RW003 Legend 1 Push Rod 2 Clutch Switch 2 Loosen clutch master cylinder push rod lock nut Turn push rod by hand to set cl...

Page 1751: ...203RW004 6 Clutch pedal engagement height inspection 1 Operate the parking brake lever and block the wheels 2 Start the engine fully step on the clutch pedal and move the shift lever to 1st position 3...

Page 1752: ...ry 2 Bleeding the slave cylinder 1 Remove the rubber cap from the bleeder screw and wipe clean the bleeder screw Connect a vinyl tube to the bleeder screw and insert the other end of the vinyl tube in...

Page 1753: ...spection and Repair 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 disassem...

Page 1754: ...2 Remove push rod 3 Remove piston and piston cup 4 Remove spring 5 Remove cylinder body Inspection and Repair Make the necessary adjustments repairs and part replacements if excessive wear or damage...

Page 1755: ...on 4 If the measured value exceeds the specified limit the slave cylinder assembly must be replaced Standard 0 07 mm 0 0028 in Limit 0 15 mm 0 0059 in 206RS005 Reassembly To reassemble follow the disa...

Page 1756: ...pring 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 3...

Page 1757: ...CLUTCH 7C 23 Torque Specifications Cont d E07RX001...

Page 1758: ...CLUTCH Special Tools ILLUSTRATION TOOL NO 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...

Page 1759: ...8A 9 Removal 8A 9 Installation 8A 9 Backup Light Bulb 8A 10 Removal 8A 10 Installation 8A 10 Dome Light Bulb 8A 10 Removal 8A 10 Installation 8A 10 Luggage Room Light Bulb 8A 11 Removal 8A 11 Install...

Page 1760: ...fastener in the proper location When you replace a fastener use ONLY the exact part number for that application ISUZU will call out those fasteners that require a replacement after removal ISUZU will...

Page 1761: ...o 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 remo...

Page 1762: ...1 Disconnect the battery ground cable 2 Open the rear cover 1 of the case 3 Remove the dust cover 4 Disconnect the bulb connector 5 Remove the clip 3 6 Remove the fog light bulb 2 801RS004 Installati...

Page 1763: ...Light Adjustment Turn the adjusting screw with a screwdriver to adjust the aim of the fog light vertically 801RW007 Front Side Marker Light Bulb Removal 1 Disconnect the battery ground cable 2 Remove...

Page 1764: ...connect the battery ground cable 2 Remove three screws and release locks at two locations to remove the rear combination light assembly 2 3 Remove the socket 3 by turning it counterclockwise 4 Turn th...

Page 1765: ...socket 803RS006 Installation To install follow the removal steps in the reverse order Stoplight Bulb Removal and Installation Refer to the Taillight Bulb in this section High Mount Stoplight Removal...

Page 1766: ...nect the battery ground cable 2 Remove the screw at the upper portion of the light bracket and remove the bracket from the fender 3 Remove the front combination light 1 4 Remove the turn signal light...

Page 1767: ...at the same time 803RS002 Installation To install follow the removal steps in the reverse order Cornering Light Bulb Removal 1 Disconnect the battery ground cable 2 Remove the screws at the upper port...

Page 1768: ...1 by turning it counterclockwise 5 Remove the bulb 2 by turning it counterclockwise while pushing it at the same time 803RS001 Installation To install follow the removal steps in the reverse order Do...

Page 1769: ...four locations 3 Remove the bulb 1 803RS007 Installation To install follow the removal steps in the reverse order Courtesy Light Bulb Removal 1 Disconnect the battery ground cable 2 Remove two screws...

Page 1770: ...he socket counterclockwise to remove it 6 Pull out the bulb from the socket 805RS008 Installation To install follow the removal steps in the reverse order Cigarette Lighter Illumination Bulb Removal 1...

Page 1771: ...dio box 4 5 Remove two screws to remove the ashtray guide 2 6 Turn the socket counterclockwise to remove it then pull out the bulb 3 742RS001 Installation To install follow the removal steps in the re...

Page 1772: ...able 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 s...

Page 1773: ...ove 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...

Page 1774: ...lock type of inflator module connector insert the connector completely and lock at outside Imperfect locking may cause malfunction of SRS system circuit 4 When installing the steering cowl 11 be sure...

Page 1775: ...toplight Switch W O Cruise Control Removal 1 Disconnect the battery ground cable 2 Disconnect the connector 3 loosen the lock nut 1 and then remove the stoplight switch 2 by turning it 310RS007 Instal...

Page 1776: ...ch 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 310RS003 Turn Signal Switch Cornering Light Switch Combination Switch Remova...

Page 1777: ...embly to remove the hazard warning switch 5 825RW024 Installation To install follow the removal steps in the reverse order noting the following point 1 Push in the switch with your fingers until it lo...

Page 1778: ...the Instrument Panel Assembly in Body Structure section 3 Remove the lower cluster assembly 2 Refer to the Instrument Panel Assembly in Body Structure section 4 Remove the instrument panel driver lowe...

Page 1779: ...and disconnect the switch connectors to remove the front console assembly 4 3 Push the lock from the back side of the front console assembly to remove the seat heater switch 5 825RW025 Installation To...

Page 1780: ...ower cover assembly 3 Refer to the Instrument Panel Assembly in Body Structure section 821RW024 5 Remove the instrument panel cluster assembly 4 Refer to the Instrument Panel Assembly in Body Structur...

Page 1781: ...14 Backup Light 15 Taillight Stoplight 16 Rear Combination Light Light Name Bulb No Rated Power Number of Bulbs Lens Color Remarks Headlight 9004 65W 45W 2 White Halogen Front Combination Turn Signal...

Page 1782: ...river 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 Indicator ABS 74 1 4W 1 Amben Meter Indicator Warning light Seat Belt 80 2W 1...

Page 1783: ...val and Installation 8B 11 Main Data and Specifications 8B 11 Service Precaution WARNING THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM SRS REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORD...

Page 1784: ...or to activate the wiper The washer motor squirts glass cleaning fluid while the washer switch is being pushed The intermittent relay is used to control motion of the wiper Windshield Wiper And Washer...

Page 1785: ...e 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 P...

Page 1786: ...bly 4 Windshield Wiper Motor Removal 1 Disconnect the battery ground cable 2 Remove the windshield wiper arm blade 3 Remove the windshield wiper motor 4 Remove the pivot assembly mounting nuts fixing...

Page 1787: ...teps in the reverse order noting the following points 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 w...

Page 1788: ...80RS011 2 Pull the end of rubber and remove the projection 3 from the click of the blade stay 2 880RS010 3 Pull the rubber out in the same direction Installation To install follow the removal steps in...

Page 1789: ...ble 2 Remove the front console assembly 1 Refer to the Instrument Panel Assembly in Body Structure section 3 Remove the lower cluster assembly 2 Refer to the Instrument Panel Assembly in Body Structur...

Page 1790: ...tall follow the removal steps in the reverse order noting the following points 1 Before installing the wiper arm blade to the motor shaft confirm that the motor stops at the auto stop position 2 Insta...

Page 1791: ...e connectors and then remove the alarm relay control unit 1 826RW020 Installation To install follow the removal steps in the reverse order Rear Washer Motor Removal 1 Disconnect the battery ground cab...

Page 1792: ...per Washer System section Rear Washer Nozzle Removal 1 Disconnect the hose 3 2 Remove the lock nut 2 and then remove the washer nozzle 1 885RS005 Installation To install follow the removal steps in th...

Page 1793: ...er Blade Rubber Removal and Installation Refer to the Windshield Wiper Blade Rubber in this section Main Data and Specifications Torque Specifications Application N m Lb Ft Lb In Windshield Wiper Moto...

Page 1794: ...CE 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...

Page 1795: ...te lighter 3 and socket 4 the bezel 5 and then remove the cigarette lighter assembly 2 826RS007 Installation To install follow the removal steps in the reverse order noting the following point 1 When...

Page 1796: ...ntil it locks securely Rod Type Antenna Removal 1 Disconnect the battery ground cable 2 Turn the antenna rod 1 counterclockwise to remove it 3 Remove three screws and nine clips to remove the fender i...

Page 1797: ...ty Glass Antenna Glass Antenna System Parts Location 890RW014 Legend 1 Glass Antenna LH 2 Glass Antenna Amplifier 3 Glass Antenna RH 4 Glass Antenna Amplifier 5 Connection with the audio side feeder c...

Page 1798: ...ove 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 glas...

Page 1799: ...Body Structure section 4 Remove the instrument panel driver lower cover assembly 3 Refer to the Instrument Panel Assembly in Body Structure section 821RW024 5 Remove the instrument panel cluster assem...

Page 1800: ...the connector 3 to remove the speaker 2 890RW013 Installation To install follow the removal steps in the reverse order Tweeter Assembly Removal 1 Disconnect the battery ground cable 2 Pull the tweeter...

Page 1801: ...onnect the battery ground cable 2 Pull the grille 1 to release the locks and then remove it 3 Remove four screws and disconnect the connector 3 to remove the speaker 2 890RW015 Installation To install...

Page 1802: ...8D 1 WIRING SYSTEM TROOPER BODY AND ACCESSORIES 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...

Page 1803: ...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...

Page 1804: ...Upshift Relay 1 18 Starter Relay 19 Not Used 20 Not Used 21 Not Used 22 Not Used 23 Cornering Relay 24 Fog Light Relay 25 Fusible Link Main 26 Fusible Link Key SW 27 Fusible Link ECM 28 Fusible Link...

Page 1805: ...1 Not Used 12 Diode Not Used 13 Fuse C 1 10A 14 Fuse C 2 15A 15 Fuse C 3 15A 16 Fuse C 4 15A 17 Fuse C 5 15A 18 Fuse C 6 10A 19 Fuse C 7 Not Used 20 Fuse C 8 15A 21 Fuse C 9 15A 22 Fuse C 10 10A 23 F...

Page 1806: ...8D 5 WIRING SYSTEM Circuit Diagram...

Page 1807: ...8D 6 WIRING SYSTEM Fuse Block Circuit...

Page 1808: ...8D 7 WIRING SYSTEM Starter and Generator...

Page 1809: ...8D 8 WIRING SYSTEM PCM 1...

Page 1810: ...8D 9 WIRING SYSTEM PCM 2...

Page 1811: ...8D 10 WIRING SYSTEM Headlight and Fog Light...

Page 1812: ...8D 11 WIRING SYSTEM Illumination Light...

Page 1813: ...8D 12 WIRING SYSTEM Turn Signal Light and Hazard Warning Light...

Page 1814: ...8D 13 WIRING SYSTEM Stoplight and Rear Defogger...

Page 1815: ...8D 14 WIRING SYSTEM Dome Light Courtesy Light Stop Light and Luggage Room Light...

Page 1816: ...8D 15 WIRING SYSTEM Door Lock W Keyless Entry...

Page 1817: ...8D 16 WIRING SYSTEM Door Lock W O Keyless Entry...

Page 1818: ...8D 17 WIRING SYSTEM Power Window...

Page 1819: ...8D 18 WIRING SYSTEM Cruise Control...

Page 1820: ...8D 19 WIRING SYSTEM ABS 1...

Page 1821: ...8D 20 WIRING SYSTEM ABS 2...

Page 1822: ...8D 21 WIRING SYSTEM A T Shift Lock...

Page 1823: ...8D 22 WIRING SYSTEM Anti theft W Keyless Entry...

Page 1824: ...8D 23 WIRING SYSTEM Windshield Wiper and Washer...

Page 1825: ...8D 24 WIRING SYSTEM Audio...

Page 1826: ...8D 25 WIRING SYSTEM Door Mirror...

Page 1827: ...8D 26 WIRING SYSTEM Meter W T O D...

Page 1828: ...8D 27 WIRING SYSTEM Meter W O T O D...

Page 1829: ...8D 28 WIRING SYSTEM A T Shift Indicator...

Page 1830: ...8D 29 WIRING SYSTEM Air Conditioning Manual...

Page 1831: ...8D 30 WIRING SYSTEM Air Conditioning Auto 1...

Page 1832: ...8D 31 WIRING SYSTEM Air Conditioning Auto 2...

Page 1833: ...8D 32 WIRING SYSTEM Sun Roof...

Page 1834: ...8D 33 WIRING SYSTEM Seat Heater...

Page 1835: ...8D 34 WIRING SYSTEM SRS Air Bag...

Page 1836: ...8D 35 WIRING SYSTEM Shift on the Fly...

Page 1837: ...8D 36 WIRING SYSTEM Torque on Demand T O D...

Page 1838: ...8D 37 WIRING SYSTEM Alarm and Relay Control Unit...

Page 1839: ...RS SERVICE INFORMATION FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT PERSONAL INJURY OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS CAUTION Always use the correct fastener in the pr...

Page 1840: ...icator 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 Li...

Page 1841: ...METER AND GAUGE 8E 3 Meter Assembly W O TOD Rear View 825RW038 Legend 10 LCD Light 11 Illumination Light 12 Illumination Light 13 Illumination Light 14 Illumination Light...

Page 1842: ...er Assembly W TOD Front View 825RW034 Legend 1 TOD Indicator 2 Tachometer 3 Warning Light Lens 4 Speedometer 5 Coolant Temperature Gauge Fuel Gauge 6 Warning Light Lens 7 Reset Knob 8 A T Shift Indica...

Page 1843: ...METER AND GAUGE 8E 5 Meter Assembly W TOD Rear View 825RW036 Legend 10 LCD Light 11 Illumination Light 12 Illumination Light 13 Illumination Light 14 Illumination Light...

Page 1844: ...8E 6 METER AND GAUGE Table for Meter Gauge Connector Terminal Connections Meter Assembly W O TOD 1 825RW037...

Page 1845: ...18 4WD indicator light 19 Ground Gauge 20 21 Winter drive indicator light 22 Oil pressure warning light 23 24 Air bag warning light 25 Power drive indicator light 26 27 Up shift indicator light 28 Tur...

Page 1846: ...8E 8 METER AND GAUGE Meter Assembly W TOD 1 825RW035...

Page 1847: ...in indicator light 20 Oil pressure warning light 21 Front 1 TOD 22 Front 2 TOD 23 Front 3 TOD 24 Lighting switch 25 Illumination controller 26 Starter switch 27 28 Winter drive indicator light 29 Powe...

Page 1848: ...onnect the meter connectors to remove the meter assembly 5 825RW031 CAUTION The removed meter assembly should be placed upright or with its face side up Installation To install follow the removal step...

Page 1849: ...the removal steps in the reverse order noting the following point 1 Tighten the vehicle speed sensor to the specified torque Torque 27 N m 20 lb ft Fuel Tank Unit Removal 1 Disconnect the battery grou...

Page 1850: ...nnector to remove the multi meter 1 821RW036 Installation To install follow the removal steps in the revers order Ambient Sensor Removal 1 Disconnect the battery ground cable 2 Disconnect the connecto...

Page 1851: ...METER AND GAUGE 8E 13 Main Data and Specifications Torque Specifications Application N m Lb Ft Lb In Vehicle Speed Sensor Fixing 27 20...

Page 1852: ...nt Fender Panel 8F 16 Parts Location 8F 16 Removal 8F 16 Installation 8F 17 Body Mounting 8F 18 Parts Location 8F 18 Removal No 1 No 2 8F 18 Removal No 3 No 6 8F 19 Installation 8F 20 General Descript...

Page 1853: ...73 Installation 8F 73 Tailgate Dove Tail Striker 8F 74 Adjustment 8F 74 Tailgate Frame Cover LH 8F 75 Parts Location 8F 75 Removal 8F 75 Installation 8F 75 Tailgate Frame Cover RH 8F 76 Removal 8F 76...

Page 1854: ...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 supple...

Page 1855: ...8F 4 BODY STRUCTURE Frame Dimensions 501RW013...

Page 1856: ...ed by taking them out forward or backward after removing the two fixing bolts on either side Front Bumper Parts Location 601RX001 Legend 1 Front Bumper Assembly 2 Front Bumper Retainer Bolt 3 Clip 4 B...

Page 1857: ...our bolts at each backbar 9 Remove front fog light assembly 10 Remove the front bumper slider 1 D Remove the two clips 4 and the two nuts 3 and release the claw from the washer 2 601RW009 Installation...

Page 1858: ...Lower Bolts 6 Reinforce Upper Bolts 7 Rear Bumper Fascia Brackets 8 Rear Bumper Fascia Bracket Screws 9 Rear Bumper Assembly 10 Rear Bumper Side Covers 11 Mud Flaps 12 Rear Bumper Assembly Fixing Bolt...

Page 1859: ...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 t...

Page 1860: ...Refer to Rear Bumper in this section 2 Remove the three bolts 2 3 Remove rear bumper slider 1 690RS004 Installation To install follow the removal steps in reverse order noting the following points 1...

Page 1861: ...When servicing these panels areas on which this material has been disturbed should be properly recoated with service type anti corrosion material Cowl Cover Parts Location 605RW003 Legend 1 Front Wipe...

Page 1862: ...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 5 R...

Page 1863: ...cowl cover D Refer to Cowl Cover in this section 2 Remove engine hood D Refer to Engine Hood in this section 3 Remove hinge fixing bolt and nut 4 Remove engine hood hinge 5 Remove hood end seal Instal...

Page 1864: ...ssembly Removal 1 Remove hood lock control lever 2 Remove inner liner 3 Remove control cable D Remove the cable fixing clips from the body panel 4 Remove radiator grille D Refer to Radiator Grille And...

Page 1865: ...its original position and check and see if the lock assembly and control lever work normally 2 Tighten the hood lock assembly fixing bolts to the specified torque Torque 10 N m 87 lb in Radiator Gril...

Page 1866: ...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 th...

Page 1867: ...4 Front Combination Lamp Assembly 5 Inner Liner Removal 1 Open the hood 2 Support the hood 3 Remove cowl cover D Refer to Cowl Cover in this section 4 Remove front combination lamp assembly D Disconne...

Page 1868: ...ect ten fixing bolts and two nuts 605RW001 Installation To install follow the removal steps in the reverse order noting the following points 1 Tighten the front fender panel fixing bolts to the specif...

Page 1869: ...ounting 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...

Page 1870: ...over the floor carpet and hold the bolt in check not to turn D No 4 Remove the bolt from under the frame 5 Loosen the mounting bolts No 5 6 on either side 6 Remove the frame side mounting and washer...

Page 1871: ...e 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...

Page 1872: ...emoval 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 diff...

Page 1873: ...8F 22 BODY STRUCTURE Body Dimension Upper Body A10RW001...

Page 1874: ...8F 23 BODY STRUCTURE A10RY00001...

Page 1875: ...8F 24 BODY STRUCTURE A10RY00002...

Page 1876: ...8F 25 BODY STRUCTURE A10RY00007...

Page 1877: ...8F 26 BODY STRUCTURE Front Section A10RW003...

Page 1878: ...8F 27 BODY STRUCTURE A10RW004...

Page 1879: ...8F 28 BODY STRUCTURE Room Section A10RW016...

Page 1880: ...8F 29 BODY STRUCTURE A10RW005...

Page 1881: ...8F 30 BODY STRUCTURE A10RW006...

Page 1882: ...8F 31 BODY STRUCTURE Rear Section A10RW007...

Page 1883: ...8F 32 BODY STRUCTURE A10RW008...

Page 1884: ...8F 33 BODY STRUCTURE Side Body A10RW018...

Page 1885: ...8F 34 BODY STRUCTURE A10RW009...

Page 1886: ...8F 35 BODY STRUCTURE A10RW017...

Page 1887: ...8F 36 BODY STRUCTURE Window Glass A10RW010...

Page 1888: ...8F 37 BODY STRUCTURE A10RW011...

Page 1889: ...8F 38 BODY STRUCTURE A10RW012...

Page 1890: ...8F 39 BODY STRUCTURE A10RW013...

Page 1891: ...nt Assembly 8 Instrument Panel Passenger Lower Cover Assembly 9 Glove Box 10 Lower Cluster Assembly 11 Front Console Assembly 12 Instrument Panel Driver Lower Cover Assembly 13 Driver Knee Bolster Ass...

Page 1892: ...screws 1 in order to disconnect the cigarette lighter 3 and the illumination 2 connectors 740RS014 4 Remove glove box D Remove the 2 fixing screws 740RT024 5 Remove instrument panel passenger lower co...

Page 1893: ...lts on the SRS adjust bracket and the cross beam under the passenger inflator module CAUTION For precautions on installation or removal of SRS air bag system refer to Supplemental RestraintSystem SRS...

Page 1894: ...lator module 3 and the 2 fixing nuts 1 and washers on the support bracket 4 then disengage the 2 clips in order to remove the passenger inflator module 827RS022 12 Remove instrument panel cluster asse...

Page 1895: ...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...

Page 1896: ...ter grille Claws at 8 positions 9 Instrument panel assembly 2 bolts SRS adjust bracket cross beam A C control cable Unit side at 3 position Instrument harness connector Driver side 5 position assist s...

Page 1897: ...ry ground cable 2 Remove instrument panel assembly D Refer to Instrument Panel Assembly in this section 3 Remove side support bracket assembly LH RH D Remove the 4 fixing bolts on both sides 4 Remove...

Page 1898: ...rake pedal link and the brake switch and remove the 4 fixing bolts and the nuts on the bracket 310RS011 8 Remove steering support bracket assembly D Remove the 2 fixing bolts upper side 1 and the 3 fi...

Page 1899: ...ge and put a marker on it 4 Remove door harness connection 2 D Pull the door harness grommet out in order to disconnect the harness connection 810RS001 5 Remove front door assembly Installation To ins...

Page 1900: ...m Pin 2 Door Harness Connection 3 Rear Door Assembly 4 Hinge Bolt Removal 1 Disconnect the battery ground cable 2 Apply a setting mark on the body side hinge 3 Remove door check arm pin 1 630RS002 4 R...

Page 1901: ...reverse order noting the following points 1 Align the door fitting to the body by refer to Body Dimensions in this section 2 Tighten the door hinge bolts to the specified torque Torque 34 N m 25 lb ft...

Page 1902: ...or Rear Door 2 Door Trim Panel 3 Check Arm Assembly 4 Check Arm Pin Bracket 5 Check Arm Pin 6 Front or Center Pillar Removal 1 Disconnect the battery ground cable 2 Remove door trim panel D Refer to...

Page 1903: ...check arm fixing nuts to the specified torque Torque 13 N m 113 lb in 3 Apply chassis grease to the check arm pin moving surface Front Window Regulator Glass And Glass Run Parts Location 631RS002 Lege...

Page 1904: ...seen 631RS004 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...

Page 1905: ...inside of the vehicle A10RS023 2 Set the glass into the door panel with the front side of the glass lowered and insert the rear side of the glass into the glass run 1 Then insert the front side of th...

Page 1906: ...indow Regulator Motor Connector 5 Door Trim Panel 6 Waterproof Sheet Removal 1 Disconnect the battery ground cable 2 Remove door trim panel D Refer to Rear Door Trim Panel in Exterior Interior Trim se...

Page 1907: ...window regulator cable fixing clip 3 from the door panel if model is equipped with power windows D Remove the window regulator 7 fixing bolts 2 and pull the regulator out from the lower hole of the do...

Page 1908: ...ivision 4 Sash Division Fixing Bolts 5 Door Trim Panel 6 Waterproof Sheet 7 Glass Removal 1 Disconnect the battery ground cable 2 Remove door trim panel 3 Remove waterproof sheet 4 Remove glass D Refe...

Page 1909: ...l steps in the reverse order noting the following points 1 Apply soap and water to the fixed glass 2 Apply soap and water to the door groove and insert the glass run 3 to the frame from the corner in...

Page 1910: ...l 1 Remove front door slash moulding D To avoid the weatherstrip 1 and pry the door sash moulding 2 out from the door panel 645RS002 Installation 1 Front door sash moulding D Assemble the edge portion...

Page 1911: ...r upper moulding 4 Remove rear door corner moulding D Avoiding the weatherstrip 3 pry the moulding 2 out from the door frame 1 645RS004 Installation To install follow the removal steps in the reverse...

Page 1912: ...r waist seal D Remove the fixing screw and pull out the waist seal 1 from the door frame while prying it up 631RS010 Installation To install follow the removal steps in the reverse order noting the fo...

Page 1913: ...8F 62 BODY STRUCTURE Rear Door Waist Seal Parts Location 651RW013 Legend 1 Rear Door Waist Seal Removal and Installation Refer to Front Door Waist Seal in this section...

Page 1914: ...nt Door Weatherstrip Parts Location 631RS008 Legend 1 Check Arm Pin 2 Bracket 3 Weather Strip 4 Clip Removal 1 Remove check arm pin 2 Remove front door weatherstrip D Pull the weatherstrip 1 out from...

Page 1915: ...me 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 631R...

Page 1916: ...8F 65 BODY STRUCTURE Rear Door Weatherstrip Parts Location 655RS001 Legend 1 Check Arm Pin 2 Rear Door Weather Strip 3 Clip Removal and Installation Refer to Front Door Weatherstrip in this section...

Page 1917: ...t door sill plate 3 Remove front door seal finisher 1 D Pull the finisher out from the body panel 635RS003 Installation To install follow the removal steps in the reverse order noting the following po...

Page 1918: ...luggage side lower cover 3 Remove rear door seal finisher 1 D Pull the rear door seal finisher 1 out from the body panel 635RS003 Installation To install follow the removal steps in the reverse order...

Page 1919: ...ssembly 5 Tailgate Trim Panel LH 6 Tailgate Assembly LH Removal 1 Disconnect the battery ground cable 2 Remove tailgate time panel LH D Refer to Tailgate Trim Panel LH in Exterior Interior Trim sectio...

Page 1920: ...he hinge fixing bolts 681RW007 Installation To install follow the removal steps in the reverse order noting the following points 1 Apply chassis grease to the tailgate hinge and the tailgate stopper m...

Page 1921: ...ction 4 Rear Combination Light RH 5 Tailgate Fixing Bolt 6 Tailgate Hinge Removal 1 Disconnect the battery ground cable 2 Remove rear combination light RH 3 Remove tailgate trim panel RH D Refer to Ta...

Page 1922: ...nge and remove the hinge fixing bolts 681RW006 Installation To install follow the removal steps in the reverse order noting the following point 1 Apply chassis grease to the tailgate hinge moving surf...

Page 1923: ...Torque 12 N m 104 lb in Tailgate Stopper Assembly Parts Location 683RS010 Legend 1 Tailgate 2 Rear Bumper 3 Tailgate Stopper Assembly Removal 1 Remove tailgate stopper assembly D Remove the five bolts...

Page 1924: ...umper 5 Tailgate LH Removal 1 Remove tailgate dove tail D Remove the two bolts from each side Installation To install follow the removal steps in the reverse order nothing the following points 1 Apply...

Page 1925: ...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...

Page 1926: ...er 2 out D Disconnect the washer tube 1 at the nozzle and pull the washer tube out from the frame cover 2 D Disconnect the rear defogger and pull the harness from the cover 684RW002 Installation To in...

Page 1927: ...me cover out from the tailgate frame 684RS011 Installation To install follow the removal steps in the reverse order noting the following points 1 Hit the lower A edge portion 2 of the tailgate frame c...

Page 1928: ...e Sash Trim Cover Removal 1 Remove tailgate sash trim cover 1 D Pry the tailgate trim cover retainers free from the tailgate panel 684RS013 Installation 1 Tailgate sash trim cover 1 D Insert the trim...

Page 1929: ...weatherstrip 1 D Pry the tailgate outer weatherstrip clips 2 free from the body panel 682RS002 Installation To install follow the removal steps in the reverse order noting the following point 1 Insert...

Page 1930: ...herstrip out from the tailgate panel Installation 1 Tailgate center weatherstrip 1 D Start assembling at the A portion 682RW006 D Clean the tailgate center weatherstrip 4 adhesive tape 2 and the butyl...

Page 1931: ...p 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 weath...

Page 1932: ...tire 2 Remove spare tire carrier by using spare tire carrier nut wrench J 34355 530RS002 Installation 1 Install the spare tire carrier D Tighten the carrier fixing bolts to the specified torque Torque...

Page 1933: ...unvisor Holder 9 Rear View Mirror 10 Multi Meter Removal 1 Disconnect the battery ground cable 2 Remove interior trim panels D Refer to the Exterior Interior Trim section 3 Remove dome light D Remove...

Page 1934: ...ove it D Disconnect the vanity mirror illumination connector 743RS006 8 Remove sun roof finisher W Sun roof 9 Remove headlining D Remove the headlining fixing clips Installation To install follow the...

Page 1935: ...10 Rear Pillar Upper Reinforcement 11 Rear Outer Roof Rail 12 Roof Panel 13 Grommet Removal 1 Disconnect the battery ground cable 2 Remove rear roof trim cover D Refer to Luggage Side and Quarter Uppe...

Page 1936: ...off the adhesive tape of the washer to install the nylon washer to the air deflector 3 667RW004 3 Install the air deflector 2 to the roof by referring to the specified values shown in the illustratio...

Page 1937: ...he battery ground cable 2 Remove roof moulding 3 Remove roof end moulding D Remove the sealing adhesive and the adhesive tape of the roof end moulding from the panel using a knife or scraper while you...

Page 1938: ...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 r...

Page 1939: ...Removal 1 Disconnect the battery ground cable 2 Remove windshield wiper D Refer to Windshield Wipper Arm Blade in Wiper Washer System section 3 Remove front cowl cover D Refer to Cowl Cover in this s...

Page 1940: ...ntire circumference of the windshield glass D Clean the remaining adhesive caulking material from the area of the body which holds the windshield 8 Remove windshield upper moulding D Taking notice of...

Page 1941: ...on where sealing adhesive is additionally filled 5 Windshield 6 Cowl Upper Rail 7 Cowl Upper Panel 8 Body Primer 9 Roof Panel 10 Sealing Adhesive 11 Windshield Upper Moulding 12 Moulding Clip 13 Front...

Page 1942: ...E 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 w...

Page 1943: ...side seal 6 Install the windshield support 2 631RS014 D Apply a sealing adhesive 4 to the circumference of the windshield 5 D Apply the sealing adhesive to the frange portion of the cowl upper rail D...

Page 1944: ...e 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 Asse...

Page 1945: ...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 fo...

Page 1946: ...Glass Moulding 5 Clip 6 Body Panel Removal 1 Remove battery ground cable 2 Remove tailgate trim panel 3 Remove tailgate sash trim cover RH only 4 Remove the tailgate frame cover D Refer to Tailgate F...

Page 1947: ...gate 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 pan...

Page 1948: ...8F 97 BODY STRUCTURE Main Data and Specifications Torque Specifications E10RW001...

Page 1949: ...8F 98 BODY STRUCTURE E10RW002...

Page 1950: ...8F 99 BODY STRUCTURE E10RX004...

Page 1951: ...8F 100 BODY STRUCTURE E10RX005...

Page 1952: ...8F 101 BODY STRUCTURE E10RW005...

Page 1953: ...8F 102 BODY STRUCTURE E10RW001...

Page 1954: ...8F 103 BODY STRUCTURE E10RX001...

Page 1955: ...8F 104 BODY STRUCTURE E10RX002...

Page 1956: ...8F 105 BODY STRUCTURE E10RX003...

Page 1957: ...8F 106 BODY STRUCTURE E10RS010...

Page 1958: ...8F 107 BODY STRUCTURE Special Tools ILLUSTRATION TOOL NO TOOL NAME J 34355 Spare Tire Carrier Nut Wrench...

Page 1959: ...llation 8G 19 Main Data and Specifications 8G 19 Service Precaution WARNING THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM SRS REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMI...

Page 1960: ...Remove the cover fixing screw from the rear inner cover if this model is equipped with the power seats 4 Remove the door sill plate 5 Remove the rear seat foot rest D Refer to the Rear Seat Foot Rest...

Page 1961: ...asher 2 Head Rest 3 Seat Back Assembly 4 Back Board Assembly 5 Reclining Device 6 Trim Cover 7 Guide Holder 8 Pad Frame Assembly 9 Slide Cover 10 Reclining Knob 11 Dial W Height Adjuster 12 Lock Sprin...

Page 1962: ...embly D Open the armrest fastener and remove the armrest fixing bolt 750RS004 6 Remove the trim cover 7 Remove the pad and frame assembly 8 Remove the hinge cover 9 Remove the back board assembly 3 D...

Page 1963: ...e wire 4 and remove the fixing bolts 750RW006 D Remove the seat belt buckle assembly 16 Remove the height adjuster 17 Remove the spacer W O height adjuster 18 Remove the seat cushion assembly 19 Remov...

Page 1964: ...se switches to move the seat to desired position independent of the position of the starter switch Disassembled View 750RS011 Legend 1 Reclining Device 2 Inner Cover 3 Rear Cover 4 Armrest Assembly 5...

Page 1965: ...the cover from the reclining device 2 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 t...

Page 1966: ...ng device connectors 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...

Page 1967: ...30 Remove the pad assembly Reassembly To reassemble follow the disassembly steps in the reverse order noting the following point 1 Tighten the fixing bolts to the specified torque D Refer to the Torqu...

Page 1968: ...tor Rear Tilt Motor Slide Motor Recliner Motor Parts Location 750RS027 Legend 1 Tilt Motor 2 Slide Motor 3 Tilt Motor 750RS028 Legend 4 Recliner Motor Removal and Installation Refer to the Power Seat...

Page 1969: ...t 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 Ref...

Page 1970: ...Cover Removal 1 Unlock the rear seat 1 lock to remove it 2 Remove the mounting bracket cover 3 Remove the fixing bolts 755RS002 4 Remove the rear seat assembly Installation To install follow the remo...

Page 1971: ...mbly 10 Band Hook Cover 11 Trim Cover 12 Pad Frame Assembly 13 Release Knob 14 Connecting Shaft 15 Release Rod 16 Linkage Bush 17 Device Cover 18 Trim Cover 19 Seat Lock Cover 20 Rear Seat Belt Buckle...

Page 1972: ...and remove the fixing nuts 11 Remove the armrest set bracket 12 Remove the armrest board 13 Remove the trim cover D Remove the trim cover fixing hog rings from the backside of the seat back D With cl...

Page 1973: ...s 1 Tighten the reclining device fixing bolts to the specified torque Torque 27 N m 20 lb ft 2 Loosen the rubber stopper lock nut 1 Adjust the stopper 3 so there is no clearance between the bottom of...

Page 1974: ...ssembly 5 Seat Back Assembly 6 Release Knob 7 Release Rod 8 Device Cover 9 Linkage Bush 10 Reclining Device 11 Connecting Shaft 12 Seat Cushion Assembly 13 Connecting Link 14 Seat Lock Cover 15 Rear S...

Page 1975: ...se attention paid to the hog rings and wire which connect the trim cover and the pad and frame assembly remove the trim cover as you turn it up 750RW011 10 Remove the pad frame assembly 11 Remove the...

Page 1976: ...orque 27 N m 20 lb ft 2 Loosen the rubber stopper lock nut 1 and adjust the stopper rubber 3 so there is no clearance between the bottom of the stopper and the carpet 2 while ensuring the rear seat is...

Page 1977: ...Remove the foot rest pad 676RS002 2 Remove the fixing nut 3 Remove the rear seat foot rest Installation To install follow the removal steps in the reverse order Main Data and Specifications Torque Sp...

Page 1978: ...8G 20 SEATS E10RW008...

Page 1979: ...Parts 8H 14 Removal 8H 14 Installation 8H 15 Tailgate Inside Lock Knob 8H 16 Removal 8H 16 Installation 8H 16 Tailgate Outside Handle and or Tailgate Lock Cylinder 8H 17 Tailgate Outside Handle and o...

Page 1980: ...will also call out the fasteners that require thread lockers or thread sealant UNLESS OTHERWISE SPECIFIED do not use supplemental coatings Paints greases or other corrosion inhibitors on threaded fas...

Page 1981: ...oor 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 To install follow the removal s...

Page 1982: ...d Parts 632RS006 Legend 1 Door Trim Panel 2 Waterproof Sheet 3 Outside Handle 4 Door Lock Cylinder 5 Clip 6 Key Switch W Anti Theft Removal 1 Disconnect the battery ground cable 2 Remove the door trim...

Page 1983: ...h connector w anti theft to remove the outside handle 632RS005 Legend 1 Outside Handle 2 To Door Lock Assembly 3 Key Switch Connector 5 Remove the key Switch 632RS007 Legend 1 Outside Handle 2 Lock Cy...

Page 1984: ...r 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...

Page 1985: ...and Associated Parts 652RS001 Legend 1 Door Trim Panel 2 Waterproof Sheet 3 Door Lock Assembly Removal 1 Disconnect the battery ground cable 2 Remove the door trim panel 3 Remove the waterproof sheet...

Page 1986: ...ndle 2 To Inside Lock Knob 3 To Inside Handle 4 To Actuator Installation To install follow the removal steps in the reverse order noting the following points 1 Apply chassis grease to the lock assembl...

Page 1987: ...rproof Sheet 3 Outside Handle Removal 1 Disconnect the battery ground cable 2 Remove the door trim panel 3 Remove the waterproof sheet D Refer to the Rear Window Regulator And Glass in Body Structure...

Page 1988: ...perates smoothly Rear Door Inside Lock Knob Link Removal 1 Disconnect the battery ground cable 2 Remove the door trim panel 3 3 Remove the waterproof sheet 2 D Refer to the Rear Window Regulator And G...

Page 1989: ...oor Trim Panel in Exterior Interior Trim section 3 Turn the door inside lock knob counterclockwise and then remove the door inside lock knob 2 632RS011 Installation To install follow the removal steps...

Page 1990: ...Waterproof Sheet 3 Tailgate Lock Assembly Removal 1 Disconnect the battery ground cable 2 Remove the tailgate trim panel LH D Refer to the Tailgate Trim Panel LH in Exterior Interior Trim section 3 Ta...

Page 1991: ...To Inside Lock Knob 2 To Actuator Installation To install follow the removal steps in the reverse order noting the following points 1 Apply chassis grease to the lock assembly and striker moving surfa...

Page 1992: ...al 4 Clip 5 Screw 6 Tailgate Lock Assembly RH Removal 1 Disconnect the battery ground cable 2 Remove the tailgate trim panel RH D Refer to Tailgate Trim Panel RH in Exterior Interior Trim section 3 Pe...

Page 1993: ...ation To install follow the removal steps in the reverse order noting the following points 1 Apply chassis grease to the lock assembly and striker moving surface 2 Tighten the tailgate lock assembly f...

Page 1994: ...Remove the tailgate trim panel LH 2 D Refer to the Tailgate Trim Panel LH in Exterior Interior Trim section 3 Take care of cushion to turn the lock knob counterclockwise and then remove the tailgate...

Page 1995: ...Associated Parts 684RW003 Legend 1 Tailgate Trim Panel LH 2 Waterproof Sheet 3 Grommet 4 Tailgate Lock Cylinder 5 Tailgate Outside Handle 6 Key Switch Removal 1 Disconnect the battery ground cable 2 R...

Page 1996: ...nder fixing bolt 2 to remove the tailgate lock cylinder 683RS008 Installation To install follow the removal steps in the reverse order noting the following points 1 For the anti theft system install t...

Page 1997: ...om 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 factor...

Page 1998: ...oor 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 wi...

Page 1999: ...e removal steps in the reverse order 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 Lo...

Page 2000: ...o activate the detect switch by the starter key Anti theft Keyless Entry Control Unit Removal 1 Disconnect the battery ground cable 2 Remove the front console assembly D Refer to the Instrument Panel...

Page 2001: ...theft Horn Removal 1 Disconnect the battery ground cable 2 Disconnect the connector and remove the fixing bolt to remove the anti theft horn 1 828RS007 Anti Theft Horn Installation To install follow...

Page 2002: ...1 Is the action complete Go to Step 3 Go to 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 Is the action complete...

Page 2003: ...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 ca...

Page 2004: ...Step 1 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 Contro...

Page 2005: ...ock 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...

Page 2006: ...AS A SUPPLEMENTAL RESTRAINT SYSTEM SRS REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING WHEN...

Page 2007: ...therstrip 2 Sun Roof Glass 3 Decoration Cover 4 Sun Roof Shim Removal 1 Open the sun roof and pull the sun roof weatherstrip out from the roof panel 2 Disconnect the battery ground cable 3 Close the s...

Page 2008: ...o install the sun roof weatherstrip so that the white marking location 4 of the weatherstrip is on the front side of the vehicle 665RW016 3 Temporarily install the glass to the sun roof frame 4 Open a...

Page 2009: ...P Sun Roof Deflector Removal 1 Open the sun roof 2 Remove the fixing screws 2 to remove the sun roof deflector 1 665RS006 Installation To install follow the removal steps in the reverse order Sunshade...

Page 2010: ...of 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 an...

Page 2011: ...Drain Hose 2 Sun Roof Frame Complete Assembly 3 Headlining 4 Sun Roof Drain Hose Removal 1 Disconnect the battery ground cable 2 Remove the headlining D Refer to the Headlining in Body Structure secti...

Page 2012: ...ame complete loosen the sun roof glass fixing nuts and adjust the sun roof glass setting position D Refer to the Sun Roof Glass in this section Disassembled View 665RW035 Legend 1 Sunshade 2 Sun Roof...

Page 2013: ...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 665RS012 Reassembly To reassembly follow the disassembly steps in the reverse...

Page 2014: ...ips Taking care not to allow the body panel grommet to be removed together with the hose pull the drain hose only to the inside of the vehicle The string should be kept as it is Installation To instal...

Page 2015: ...er Removal 1 Disconnect the battery ground cable 2 Remove the rear fender inner liner 3 Remove the headlining D Refer to the Headlining in Body Structure section 4 Disconnect the drive hose at the fra...

Page 2016: ...uting cut the leading edge so that the protrusion is within 50 mm 2 0 in Sun Roof Switch General Description Sun roof operation can be controlled by pushing continuously the sun roof switch to activat...

Page 2017: ...attery ground cable 2 Remove the headlining 2 D Refer to the Headlining in Body Structure section 3 Disconnect the connector and remove three nuts and two screws to remove the sun roof motor 1 665RW03...

Page 2018: ...SUN ROOF CONVERTIBLE TOP 8I 13 Main Data and Specifications Torque Specifications Application N m Lb Ft Lb In Sun Roof Frame Complete Assembly Fixing Bolts 10 87 Sun Roof Glass Fixing Screws 10 87...

Page 2019: ...t Pillar Trim Cover 8J 19 Front Pillar Trim Cover and Associated Parts 8J 19 Removal 8J 19 Installation 8J 20 Center Pillar Assist Grip 8J 20 Parts Location 8J 20 Removal and Installation 8J 20 Assist...

Page 2020: ...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 FOLLO...

Page 2021: ...ps of the trim panel D Take care not to damage the harness and the controller on the back of the trim panel 643RS007 Installation To install follow the removal steps in the reverse order noting the fo...

Page 2022: ...moval 1 Disconnect the battery ground cable 2 Remove the shift knob M T transfer knob 4x4 only 3 Remove the front console assembly D Remove four fixing screws and disconnect the switch connectors 4 Re...

Page 2023: ...sembly 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...

Page 2024: ...Window Switch 2 Door Mirror Cover Tweeter 3 Door Wood Panel 4 Door Trim Panel 5 Courtesy Light 6 Front Speaker 7 Speaker Cover 8 Regulator Handle 9 Inside Handle Fixing Screw 10 Inside Handle 11 Hook...

Page 2025: ...switch connector 825RW045 5 Remove the speaker cover 6 Remove the front speaker D Remove the front speaker fixing screws in order to disconnect the speaker connector 7 Remove the inside handle fixing...

Page 2026: ...007 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 t...

Page 2027: ...im 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 o...

Page 2028: ...egend 1 Power Window Switch 2 Door Wood Panel 3 Courtesy Light 4 Door Trim Panel 5 Washer 6 Clip 7 Regulator Handle 8 Inside Handle Fixing Screw 9 Inside Handle Removal 1 Disconnect the battery ground...

Page 2029: ...door with the inside handle 632RW002 5 Remove the door trim panel 6 D Remove two fixing screws 8 to take off seven clips 7 from the door panel 655RS004 D Unplug the courtesy light connector to lift t...

Page 2030: ...nto 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 t...

Page 2031: ...Removal 1 Remove the door trim panel 1 D Refer to the Front Rear Door Trim Panel in this section 2 Remove the door wood panel assembly 2 D Remove four door wood panel assembly fixing screws and washer...

Page 2032: ...Remove the door mirror connector 4 Remove the door mirror Installation To install follow the removal steps in the reverse order noting the following points 1 When you install the door mirror install...

Page 2033: ...r 5 Luggage Side Trim Cover 6 Rear End Floor Trim Cover 7 Luggage Side Cap 8 Speaker Grille 9 Rear Speaker 10 Clip 11 Luggage Room Light 12 Rear Roof Trim Cover Removal 1 Disconnect the battery ground...

Page 2034: ...m cover retainers free from the body panel 666RS001 8 Remove the speaker grille 687RS003 9 Remove the rear speaker D Remove the rear speaker fixing screws and disconnect the connector 10 Remove the re...

Page 2035: ...lar and Roof Side Trim Cover Center Pillar Roof Side Trim Cover and Associated Parts 643RW003 Legend 1 Roof Side Trim Cover 2 Front Pillar Trim Cover 3 Assist Grip RH only 4 Adjust Shoulder Anchor Ass...

Page 2036: ...hen slide the trim cover downward 643RS003 4 Remove the front seat belt anchor bolt cover 3 and the anchor bolt 4 760RW006 5 Remove the center pillar upper trim cover 6 D Turn up the finisher 5 and pr...

Page 2037: ...ing the following point 1 Install the seat belt anchor bolts to the specified torque Torque 39 N m 29 lb ft Front Pillar Trim Cover Front Pillar Trim Cover and Associated Parts 743RS003 Legend 1 Roof...

Page 2038: ...trim cover retainers free from the body panel 635RW001 Installation To install follow the removal steps in the reverse order Center Pillar Assist Grip Parts Location 743RS004 Legend 1 Center Pillar A...

Page 2039: ...EXTERIOR INTERIOR TRIM 8J 21 Assist Grip Parts Location 743RS005 Legend 1 Assist Grip Removal and Installation Refer to the Center Pillar and Roof Side Trim Cover in this section...

Page 2040: ...sembly 8 Fuel Filler Lid Opener 9 Front Seat RH 10 Center Pillar Lower Trim Cover 11 Rear Door Sill Plate RH 12 Luggage Side Trim Panel RH Removal 1 Disconnect the battery ground cable 2 Remove the fr...

Page 2041: ...pull out the cable toward the fuel filter lid Installation To install follow the removal steps in the reverse order noting the following points 1 Insert the opener cable 2 into the body panel 1 secure...

Page 2042: ...rotector 2 Inner Liner 3 Spare Nut 4 Fixing Screw 5 Rocker Protector 6 Outer Side Panel 7 Outer Wheel House Panel 8 Fixing Clip 9 Outer Rocker Panel 10 Door Panel 11 Front Rocker Protector 12 Clip W R...

Page 2043: ...oor Wheel Opening Extension Assembly Removal 1 Remove the front rocker protector assembly D Loosen and pull clips and remove the front rocker protector assembly 2 Remove the rear rocker protector asse...

Page 2044: ...ge riveted portions Disengage three clips peel off the bonded portions with two double surface adhesive tape and the rear door wheel opening extension assembly Installation To install follow the remov...

Page 2045: ...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...

Page 2046: ...the ventilation assembly retainers free from the body panel 641RS002 2 Remove the outlet valve assembly Installation 1 Install the outlet valve assembly D Insert the upper and lower catches of the ou...

Page 2047: ...1 Tailgate Trim Panel LH 2 Clip 3 Tailgate Panel 4 Cap and Screw Removal 1 Disconnect the battery ground cable 2 Remove the cap and screw 3 Remove the tailgate trim panel LH D Pry the trim panel retai...

Page 2048: ...lgate Trim Panel Removal 1 Disconnect the battery ground cable 2 Remove the tailgate trim panel RH D Pry trim panel retainer free from the tailgate panel 684RS003 Installation 1 Install the trim panel...

Page 2049: ...lips which connect the floor carpet and the luggage floor box cover 3 Remove the luggage floor box Installation To install follow the removal steps in the reverse order Rope Hook Set Rope Hook Set and...

Page 2050: ...shift lever knob D Disconnect the seat heater switch connectors if so equipped D Disconnect the door mirror switch connectors D Disconnect the power winter switch connectors A T only 3 Remove the door...

Page 2051: ...e 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 1...

Page 2052: ...connect the battery ground cable 2 Remove the window regulator assembly 1 D Refer to Front Window Regulator Glass and Glass Run in Body Structure section 3 Remove the power window motor 2 D Remove thr...

Page 2053: ...EXTERIOR INTERIOR TRIM 8J 35 Main Data and Specifications Torque Specifications Application N m Lb Ft Lb In Door Mirror Fixing Bolts 8 69 Seat Belt Anchor Bolts 39 29 Hook Fixing Bolt 13 113...

Page 2054: ...IS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM SRS REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS...

Page 2055: ...ront seat belt anchor bolt cover and anchor bolt Upper Side D Refer to Center Pillar and Roof Side Trim Cover in Exterior Interior Trim section 5 Remove the seat belt lower anchor bolt and screw and t...

Page 2056: ...ts normal operation CAUTION Do not disassemble the retractor Installation To install follow the removal steps in the reverse order noting the following points CAUTION The front seat belt for 99model i...

Page 2057: ...sure it is not locked within 15 in any directions and it remains locked at 45 or larger 2 ELR lock check D When the seat belt is drawn slowly with the retractor installed make sure it is not locked A...

Page 2058: ...at Lock Cover Removal 1 Remove the catch portions 2 3 of the seat lock assembly 4 from the cover and then remove the seat lock cover 1 760RW016 2 Remove the rear seat buckle assembly Installation 1 Fi...

Page 2059: ...t lock fixing bolts to the specified torque Torque 42 N m 31 lb ft Rear Seat Lock Assembly Bench Type Removal 1 Remove the seat lock cover 3 2 Remove the rear seat belt buckle assembly 1 3 Disconnect...

Page 2060: ...at three places on the luggage floor panel Remove the center plug from the floor panel Install the bracket to the hole where the plug is removed Alternatively the bracket may be installed in the right...

Page 2061: ...pplication N m Lb Ft Lb In 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...

Page 2062: ...and Specifications 9J 42 Service Precaution WARNING THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM SRS REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFO...

Page 2063: ...t require it If the above conditions are not followed parts or system damage could result Restraint Devices 827RW006 Legend 1 Deployed Air Bag 2 Knee Bolster 3 Seat Belt The Supplemental Restraint Sys...

Page 2064: ...ir bag assembly which will cause deployment of the air bags in the event of a frontal crash of sufficient force up to 30 degrees off the centerline of the vehicle The air bag assemblies are only suppl...

Page 2065: ...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 VEHI...

Page 2066: ...nition switch is at the ON or START positions with the SDM disconnected 827RW004 Legend 1 SDM 2 SRS Harness 3 Connector Position Assurance Air Bag Warning Lamp Ignition voltage is applied to the AIR B...

Page 2067: ...iver 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 827RS008 There is...

Page 2068: ...iver 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 ini...

Page 2069: ...ostic 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 Hist...

Page 2070: ...d difference model year air bag assembly The air bag assembly has identification colors on the bar code label from 00 model as follows Yellow color for driver air bag assembly White color for passenge...

Page 2071: ...FAILURE TO FOLLOW PROCEDURES COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT PERSONAL INJURY OR OTHERWISE UNNEEDED SRS REPAIRS The SDM in Driver Passenger SRS can maintain sufficient voltage to cause a d...

Page 2072: ...bly to be thrown through the air in the unlikely event of an accidental deployment 827RV004 WARNING WHEN CARRYING A LIVE AIR BAG ASSEMBLY MAKE SURE THE BAG OPENING IS POINTED AWAY FROM YOU IN CASE OF...

Page 2073: ...d be read fully before they are performed The following procedure requires use of J 42986 SRS deployment harness with appropriate pigtail adapter Do not attempt procedure without J 42986 adapter WARNI...

Page 2074: ...ector 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 object...

Page 2075: ...r source and that its two banana plugs have been shorted together by fully seating one banana plug into the other 25 Disconnect the pigtail adapter from the driver air bag assembly WARNING WHEN STORIN...

Page 2076: ...that no loose or flammable objects are within the deployment area 7 Place the J 41497 on the bench vice This is necessary to provide sufficient stabilization of the fixture during deployment 8 Attach...

Page 2077: ...WILL BE HOT DO NOT TOUCH THE METAL AREAS OF THE AIR BAG ASSEMBLY FOR ABOUT THIRTY MINUTES AFTER DEPLOYMENT IF THE DEPLOYED AIR BAG ASSEMBLY MUST BE MOVED BEFORE IT IS COOL WEAR GLOVES AND HANDLE BY T...

Page 2078: ...R BAG WHEN A POWER SOURCE IS CONNECTED TO IT CONNECTING THE DEPLOYMENT WIRES TO THE POWER SOURCE SHOULD ALWAYS BE THE FINAL STEP IN THE AIR BAG ASSEMBLY DEPLOYMENT PROCEDURE FAILURE TO FOLLOW PROCEDUR...

Page 2079: ...oves and safety glasses to protect your hands and eyes from possible irritation and heat when handling the deployed air bag assembly After an air bag assembly has been deployed the surface of the air...

Page 2080: ...ESULT 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...

Page 2081: ...river 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...

Page 2082: ...pter 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 901RW106 The J 42986 SRS Depl...

Page 2083: ...card with the Tech 2 the following steps must be performed 1 Insert the Isuzu 98 System PCMCIA card 1 into the Tech 2 5 2 Connect the SAE 16 19 adapter 3 to the DLC cable 4 3 Connect the DLC cable to...

Page 2084: ...LEMENTAL RESTRAINT SYSTEM 9J 23 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 060RY027 060RW...

Page 2085: ...ve key 1 Connect yellow 2 pin connector passenger air bag assembly 2 Install glove box assembly Refer to Passenger Air Bag Assembly Replacement in this section 3 Connect yellow 2 pin connector at the...

Page 2086: ...cement 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 produ...

Page 2087: ...ENTAL RESTRAINT SYSTEM 9J 26 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 8...

Page 2088: ...ONT OF THE VEHICLE SDM is specifically calibrated and is keyed to the SDM location SRS wiring harness Caution should be used to ensure proper location of the SDM The keying of the SDM to its location...

Page 2089: ...SUPPLEMENTAL RESTRAINT SYSTEM 9J 28 5 Enable the SRS Refer to Enabling the SRS in this section 827RW026 Legend 1 SDM 2 SRS Harness 3 Connector Position Assurance...

Page 2090: ...ING 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 FAC...

Page 2091: ...to specified sequence as shown in figure Torque 8 N m 69 lb in CAUTION Never use the air bag assembly from another vehicle and difference model year air bag assembly The air bag assembly has identific...

Page 2092: ...CH OR OTHER SURFACE ALWAYS FACE BAG AND RIM COVER UP AWAY FROM THE SURFACE NEVER REST A STEERING COLUMN ASSEMBLY ON THE STEERING WHEEL WITH THE AIR BAG ASSEMBLY FACE DOWN AND COLUMN VERTICAL THIS IS N...

Page 2093: ...l 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 ener...

Page 2094: ...bly from another vehicle and difference model year air bag assembly The air bag assembly has identification colors on the bar code label from 00 model as follows Yellow color for driver air bag assemb...

Page 2095: ...SSEMBLY ON A BENCH OR OTHER SURFACE ALWAYS FACE BAG AND RIM COVER UP AWAY FROM THE SURFACE NEVER REST A STEERING COLUMN ASSEMBLY ON THE STEERING WHEEL WITH THE AIR BAG ASSEMBLY FACE DOWN AND COLUMN VE...

Page 2096: ...el in the direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel The steering shaft is designed as an energy absorbing unit 14 Remove the combination...

Page 2097: ...nnect air bag to wiring harness connector NOTE Pass the lead wire through the tabs on the plastic cover wire protector of air to prevent lead wire from being pinches 827RT009 12 Install air bag into s...

Page 2098: ...THER SURFACE ALWAYS FACE BAG AND RIM COVER UP AWAY FROM THE SURFACE NEVER REST A STEERING COLUMN ASSEMBLY ON THE STEERING WHEEL WITH THE AIR BAG ASSEMBLY FACE DOWN AND COLUMN VERTICAL THIS IS NECESSAR...

Page 2099: ...t the wiring harness connectors located at the base of steering column CAUTION Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt t...

Page 2100: ...the specified torque Torque 31 N m 23 lb ft 5 Install steering lock cylinder assembly 6 Connect shift lock cable For A T 7 Install cushion rubber 8 Install snap ring 9 Install the combination switch a...

Page 2101: ...being pinched 827RT009 17 Install air bag into steering wheel and tighten bolts to specified sequence as shown in figure Torque 8 8 N m 78 lb in CAUTION Never use the air bag assembly from another veh...

Page 2102: ...ASSEMBLY ON THE STEERING WHEEL WITH THE AIR BAG ASSEMBLY FACE DOWN AND COLUMN VERTICAL THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG ASSEMBLY TO EXPAND IN THE UNLIKELY EVENT...

Page 2103: ...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 1...

Page 2104: ...71 Internal SDM Fault 9J1 40 Service Precaution WARNING THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM SRS REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE...

Page 2105: ...ere last cleared during service 1 Active Codes Faults that are presently detected this ignition cycle Active codes are stored in RAM Random Access Memory 2 History Codes All faults detected since the...

Page 2106: ...l 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 al...

Page 2107: ...S Diagnostic System Check after all repair or diagnostic procedures will ensure that the repair has been made correctly and that no other malfunctions exist Circuit Description When the ignition switc...

Page 2108: ...ouble code s displayed Ignition switch OFF When DTC 71 is set go to DTC 71 Chart For all other history codes refer to Diagnostic Aids For that specific DTC A history DTC indicates the malfunction has...

Page 2109: ...scan tool Clear Codes command If DTCs 51 53 are not indicated then DTC 71 is not existing DTCs 51 53 and 71 can not be cleared after a Clear Codes command is issued Chart Test Description Number s bel...

Page 2110: ...to verify the need for SDM replacement 3 Ignition switch OFF 4 Reconnect all SRS components ensure all components are properly mounted 5 Ensure the ignition switch has been OFF for at least 15 seconds...

Page 2111: ...em 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 DT...

Page 2112: ...F Replace SDM Go to Step 5 Connect SDM securely to de activate shorting clip in SDM harness connector Go to Step 5 3 Using scan tool request SRS data list Is ignition more than 9 volts Go to Step 4 Ig...

Page 2113: ...ll be still OFF solid with no DTCs set Chart Test description Number s below refer to step number s on the diagnostic chart 1 This test decides whether power is available to SDM warning lamp power fee...

Page 2114: ...If ok then remove and inspect AIR BAG bulb Is bulb good Go to Step 5 Replace bulb Go to Step 6 4 1 Ignition switch OFF 2 Disconnect instrument meter cluster harness connector 3 Ignition switch ON 4 M...

Page 2115: ...column and behind the glove box assembly 2 Disconnect SDM 3 Replace C 10 fuse 4 Ignition switch ON wait 10 seconds 5 Ignition switch OFF 6 Remove and inspection C 10 fuse Is fuse good Install C 10 fus...

Page 2116: ...nnector terminal contact is above a specified value This test is run once each ignition cycle during the Resistance Measurement Test when 1 No higher priority faults are detected during Turn ON 2 Igni...

Page 2117: ...ct 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 3 Ignition switch ON Is DTC 15 current G...

Page 2118: ...ector terminal contact is above a specified value This test is run once each ignition cycle during the Resistance Measurement Test when 1 No higher priority faults are detected during Turn ON 2 Igniti...

Page 2119: ...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 3 Ignition switch ON Is DTC 16 Current Go to Step 5 Go t...

Page 2120: ...inal 16 is above or equal to a specified value for 500 milliseconds during Continuous Monitoring Action Taken SDM turns ON the AIR BAG warning lamp and sets a diagnostic trouble code DTC Will Clear Wh...

Page 2121: ...econnect the passenger air bag assembly 2 pin connector 3 Ignition switch ON Is DTC 17 current Go to Step 5 Go to Step 7 5 1 Ignition switch Off 2 Disconnect SRS coil and passenger air bag assembly ye...

Page 2122: ...n once each ignition cycle and Continuous Monitoring Action Taken SDM turns ON the AIR BAG warning lamp and sets a diagnostic trouble code DTC Will Clear When This malfunction is no longer occurring a...

Page 2123: ...ly 3 Leave driver air bag assembly connected 4 Connect SRS driver passenger load tool J 41433 and appropriate adapter to passenger air bag assembly harness connector 5 Ignition switch ON Is DTC 18 cur...

Page 2124: ...the AIR BAG warning lamp and sets DTC 19 and also DTC 71 DTC Will Clear When The SDM is replaced DTC Chart Test Description Number s below refer to step number s on the diagnostic chart 2 This test d...

Page 2125: ...passenger air bag assembly yellow 2 pin connector behind the glove box assembly 3 Leave driver air bag assembly connected 4 Connect SRS driver passenger load tool J 41433 and appropriate adapter to p...

Page 2126: ...assembly harness wiring CKTs IB05 YEL and IB06 YEL BLK and connector terminal contact is above a specified value This test run once each ignition cycle during the Resistance Measurement Test when 1 No...

Page 2127: ...t loop resistance Is driver resistance more than 3 7 ohms Go to Step 3 Go to Chart A 3 1 Ignition switch OFF 2 Disconnect SRS coil assembly yellow 2 pin connector located at base of steering column is...

Page 2128: ...41433 on the top of steering column 4 Reconnect SRS coil assembly harness connector as the base of steering column 5 Ignition switch ON Is DTC 21 current Ignition switch OFF Replace SRS coil assembly...

Page 2129: ...B06 YEL BLKand connector terminal contact is above a specified value This test is run once each ignition cycle during the Resistance Measurement Test when 1 No higher priority faults are detected duri...

Page 2130: ...f steering column 2 If ok reconnect the SRS coil assembly yellow 2 pin connector 3 Ignition switch ON Is DTC 22 current Go to Step 5 Go to Step 8 5 1 Ignition switch OFF 2 Disconnect SRS coil and pass...

Page 2131: ...Driver Bag Low is below a specified value DTC 24 will set Action Taken SDM turns ON the AIR BAG warning lamp and sets a diagnostic trouble code DTC Will Clear When The malfunction is no longer occurr...

Page 2132: ...ch OFF 2 Disconnect SDM 3 Disconnect SRS driver passenger load tool 4 Measure resistance on SDM harness connector 3 to terminal 6 ground Does J 39200 display OL infinite Go to Step 5 Replace SRS harne...

Page 2133: ...l Clear When The SDM is replaced DTC Chart Test Description Number s below refer to step number s on the diagnostic chart 2 This test determines whether the SDM is malfunctioning 3 This test isolates...

Page 2134: ...harness connector 4 Ignition switch ON Is driver sense LO more than 3 5 volts Go to Step 4 Go to Step 6 4 1 Ignition switch OFF 2 Disconnect SDM 3 Disconnect SRS driver passenger load tool 4 Measure r...

Page 2135: ...ets a diagnostic trouble code DTC Will Clear When The voltage difference between Driver Bag High terminal 3 and Driver Bag Low terminal 4 is below a specified value for 500 milliseconds during Continu...

Page 2136: ...in connector located at the base of steering column and behind the glove box assembly 3 Connect SRS driver passenger load tool J 41433 and appropriate adapter to SRS coil and passenger air bag assembl...

Page 2137: ...y deploying the air bags and causing DTC 51 to set DTC Will Set When The SDM detects a frontal crash up to 30 degrees off the centerline of the vehicle of sufficient force to warrant deployment of the...

Page 2138: ...No 1 Was the SRS Diagnostic System Check performed Go to Step 2 Go to the SRS Diagnostic System Check 2 Ignition switch OFF Have air bag assemblies deployed Replace components and perform inspections...

Page 2139: ...loyment situation in one or both air bag assemblies DTC Will Set When The SDM detects a frontal crash up to 30 degrees off the centerline of the vehicle of sufficient force to warrant deployment of th...

Page 2140: ...INJURY Step Action Yes No 1 Was the SRS Diagnostic System Check performed Go to Step 2 Go to the SRS Diagnostic System Check 2 Ignition switch OFF Have air bag assembles deployed Replace components a...

Page 2141: ...value and the output state does not match the commanded state of the lamp driver for 500 milliseconds DTC 61 is set DTC Will Set When Ignition 1 voltage is in the specified value and the output state...

Page 2142: ...thin 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 perfor...

Page 2143: ...8 Arming sensor fault 9 Diagnostic current faults 10 DTC 19 11 DTC 25 12 DTC 51 13 DTC 53 DTC Will Set When Any of the above indicated malfunctions are detected by the SDM The malfunctions described a...

Page 2144: ...as 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 D...

Page 2145: ...ed 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 corre...

Page 2146: ...d on D When the brake pedal is pressed D When the clutch pedal is pressed M T D When the select lever is shifted to any position other than D 3 2 or L A T D When the cancel switch is operated D When t...

Page 2147: ...e 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 Refer to the Clutch Control removal and installatio...

Page 2148: ...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...

Page 2149: ...on 6 Disconnect the and push the lock from the side of the instrument panel cluster assembly to remove the cruise control main switch 4 821RW079 Installation To install follow the removal steps in the...

Page 2150: ...IMES WITHIN 1 SECOND DIAGNOSIS IS ENABLED IN 130 SECONDS AFTER THE SWITCH OPERATED P0566 CRUISE CAN CEL CIRCUIT D D THE SWITCH CONTACT REMAINS ON FOR 40 SECONDS OR MORE D NOISES ARE GENERATED BY THE P...

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