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Mazda B-Series 1997, Workshop Manual

The Mazda B-Series 1997 Workshop Manual is a comprehensive guide for DIY enthusiasts and mechanics. This manual provides detailed instructions and diagrams for servicing, maintenance, and repairs. Download your free copy from manualshive.com to keep your B-Series running smoothly for years to come.

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Summary of Contents for B-Series 1997

Page 1: ...Mazda B Series Workshop Manual 1997 Mazda Motor Corporation Printed in U S A 7 96 9999 95 0228 97...

Page 2: ...followed to reduce the risk of injury and the risk that improper service or repair may damage the vehicle or render it unsafe It is also important to understand that the Warnings and Cautions are not...

Page 3: ...pt up to date Mazda Motor Corporation reservesthe right to alter the specificationsandcontentsof this manualwithout obligationor advancenotice All rights reserved No part of this book may be reproduce...

Page 4: ...VEHICLE IDENTIFICATIONNUMBERS VIN...

Page 5: ...EMBLY GI 6 ASSEMBLY GI 7 ADJUSTMENTS GI 8 RUBBER PARTS AND TUBING GI 8 JACK AND SAFETY STAND RIGID RACK POSITIONS GI 9 FRONT END GI 10 REAR END GI 10 VEHICLE LIFT 2 SUPPORTTYPE POSITIONS GI 11 FRONT E...

Page 6: ...ill be jeopardized by the use of incorrect methods or tools 4BUGIX 003 POSSIBLE LOSS OF WARRANTY The manufacturer swarrantyon Mazdavehicles andenginescanbevoidedif improperserviceor repairs are perfor...

Page 7: ...the needed Special Service Tool SST for the service operation that it precedes Gather all necessary SSTs before beginningwork Example MANUAL STEERING 1 PREPARATION SST NUMBER USAGE SST 49 0118 850C Pu...

Page 8: ...elated to service procedures are shown under the illustration Refer to this information when servicing the related part Example 73 07 7 4 10 9 54 79 1 1SELECTIVE 21 SHOWS EXPENDABLE PARTS SHOWS APPLIC...

Page 9: ...n special oil or grease is needed this is shown in the illustration 4BUGIX 009 NOTES CAUTIONS AND WARNINGS As you readthroughthe procedures you will comeacross NOTES CAUTIONS andWARNINGS Each one is t...

Page 10: ...s are specificallyidenti fied If a Mazda special service tool is not suggested please use an equivalent tool MGll005 A 4BUGIX 013 SPECIAL TOOLS Use special tools when they are required I J MG11006 A 4...

Page 11: ...se that will be reused 3 Cleaning parts for reuse All partsto be reusedshould be carefully and thoroughly cleaned in the appropriate method I I MGI1011 A 4BllGIX 019 ASSEMBLY Standard values such as t...

Page 12: ...moving components of parts 3 Specified oil or grease should be applied at the pre scribed locations suchas oil seals beforeassembly I I MG11013 A 4BUGIX 020 ADJUSTMENTS Use suitable gauges and or tes...

Page 13: ...unthe enginewith onewheel off the ground such as when changing a tire The wheel still on the ground could cause the vehicle to move When lifting a vehicle with the vehicle jack or any floor jack set t...

Page 14: ...JACK AND SAFETY STAND RIGID RACK POSITIONS FRONT END Jack position Safety stand positions At the center of the crossrnember On both sides of the frame rail...

Page 15: ...kets or the stabilizer bar brackets When raising a vehicle on a 2 support type lift care shouldbetakento positionthe vehiclesothat the adapter pads do not damage the axle carrier casting or contact th...

Page 16: ......

Page 17: ...roper procedure Note Onfour wheel drivevehicles if a distance of 80 km 50 miles or a speed of 56 kmlh 35 mph must be exceeded disconnect the propeller shafts Maximumspeed is88kmlh 55 mph with propelle...

Page 18: ...he FREE position 5 Vehicle speed should not exceed 88kmlh 55 mph regardless of which wheels are on or off the ground 4BUGIX 029 Towing with an electronic shift control system transfer case For manual...

Page 19: ...houldbe usedto lift andtow allvehicles When attaching the towbar take care to avoid damage to the license plate frame and the bumper TOWING SLING rC 1 CROSSBEAMSPACERBLOCKS MATERIAL CROSSBEAMS ONE 4 X...

Page 20: ...ntothe slots inthe frame forward of the wheels 2 Position a 4x4 wood block under the bumper behindthe airdam and forward of the crossmember 3 Positionthe towbar under the airdam and againstthe 4x4 woo...

Page 21: ...t of the 4x4 block as shown in the illustration T HooK CHAINS 5 Attach safety chains to the axle inboard of the springs Caution Use care to prevent damage to the axle mounting brake pipes I I MGll030...

Page 22: ...red by Ford for Mazda Motor Corporation GVWR Brake System I Vin Code R12 R13 R16 1 Indicatesthe check digit for the vehicle Manufacturedby Ford for Mazda Motor Corporation Mfr I Class C Class D Series...

Page 23: ...identi fies the exterior paint color The letters and or number under Bodydesignatethe interiortrim seat andthe body type The letters and or numbers under Tape designate the external body side tape st...

Page 24: ...Ib 9 Rear tire size 10 Rim size 11 Rear tire cold kPa psi 12 Vehicle identification number I 5BUGIX 003 13 Type vehicle 14 Exterior paint codes 15 Wheelbase 16 Model codes and GVWs 17 Seat types and...

Page 25: ...c Br ght Sapph re Met c c I 3181125 1 Cab Plus I O SWB Short wheel base Q LWB Longwheel base MGll064 A TR YZ FL Medium Graphite Met clc Oxford White clc Toreador Red Met clc ulodel codes and GVWs Ser...

Page 26: ...Med Graphite Light PrairieTan Vinyl I Split bench Bodycloth HIB bucket Tape accent codes Code Cloth Cloth Cloth Cloth Cloth Sport bucket Sport bucket Premium bucket Split bench Sport bucket I S 1 Sil...

Page 27: ...transmission EEC Evaporativeemission control system EGR Exhaust gas recirculation ELR Emergency locking retractor ETR Electricaltuning radio EX Exhaust Fig Figure HAT Hydraulically controlledautomatic...

Page 28: ...tinuous Fuel Injection system 1 Svstem BAR0 B Cooling Fan Control Barometric Pressure sensor Battery Posltive Voltage FC Fan Control TWC I Three Way Catalytic Converter El Electronic lgnltlon ECM PCM...

Page 29: ...Air Conditioner sensor 1 5 I I Solenoid Valve ISC I IAC 1 Idle Air Control valve I I I I I Test Modes DTM I DiagnosticTest Mode I 6 I I 1 TP 1 Throttle Sensor 1 Throttle Position sensor I I I Warning...

Page 30: ...a LINE GROUND MGll036 A 4BUGIX 056 The DC voltmeter is used to measure circuit voltage A voltmeter with a rangeof 15V or moreis usedby connect ingthe positive probe redleadwire to the pointwhere volt...

Page 31: ...connector Never pull on the wiring harness when disconnecting connectors Connectors can be removed by pressing or pulling the lock lever as shown Locking of connector When locking connectors make sur...

Page 32: ...inals Inspection Pull lightly on individual wires to check that they are secured in the terminal Replacement of terminals Use the appropriate tools to remove the terminal as shown When installing the...

Page 33: ...replacing a fuse be sure to replace it with one of specified capacity If a fuse again fails after it has been replaced the circuit probably has a short circuit and the wiring should be checked 2 Be su...

Page 34: ...ring Harness Wiring color codes Two colorwiresare indicatedby atwo colorcodesymbol The first color indicatesthe basecolor of the wire and the secondthe color of the stripe e g G Y greenwire with a yel...

Page 35: ...OT IDLE I 2500 RPM I Units I LONGFTI LOAD I I I ILONGFTI I 120 20 1 120 I 120 1 1 DESCRIPTION Cont Code Counter Secondary Air Status Engine Coolant Temperature Fuel System Status Bank 1 Fuel System St...

Page 36: ...OT IDLE I 2500 RPM I Units I LONGFTI LONGFT2 LOAD MAF ILONGFTI 1 420 20 1 420 20 1 1 I I I 1LOAD I 22 28 1 23 29 1 I 20 20 20 20 22 24 4 3 4 8 20 20 20 20 22 24 17 5 19 MAF SHRTFTI SHRTFT2 SHRTFTII SH...

Page 37: ...ES A 15 REPLACEMENTOF SPARK PL UGS A 15 INSPECTION OF BRAKE LINES HOSES AND CONNECTIONS A 16 INSPECTIONOF DISC BRAKE A 16 INSPECTIONOF DRUM BRAKE A 16 REPLACEMENTOF BRAKE FLUID A 16 INSPECTIONOF FRONT...

Page 38: ...controlsystemfor loose Check heater air conditioner defroster covers antennas etc missing or damaged components and ventilation system Wash the vehicle and perform detailed EXTERIOR ON HOIST Check fue...

Page 39: ...ns below apply Follow Schedule 2 Unique Driving Conditions if any of the conditions below apply Repeated short distancedriving when outside temperatures remain below freezing Driving in dusty conditio...

Page 40: ...Ilnings llnes and hoses Exhaust system for leaks damage looseness Exhaust system shielding for trapped mater al I I Propeller shaft U jolnts f equ pped wlth grease flttlngs L L L I I I I R I 1 I i I I...

Page 41: ...eel lug nuts have been loosened 2 Replace rear axle lube quantities every 160 000 km 100 000 miles or if the axles have beensubmerged inwater Otherwise the lubeshouldnotbecheckedor changed unless a le...

Page 42: ...yoke f equ pped Clutch reservoir fluid level Rear axle lube Replace air cleaner every 30 months or every 30 000 miles 48 000 km 3 5 Maintenance Item i i I I i i Chassis and body L 18 30 km Automatic t...

Page 43: ...n 16 km 10 miles when outside temperatures remain below freezing Towing a trailer or carrying maximum loads Operating in severe dust conditions Operatingduring hot weather in stop and go rush hour tra...

Page 44: ...then Mazda recommends you increasethe frequency of oil and filter changes as follows Intervalequivalent to 200 ENGINE HOURSof use Since mostvehicles are notequippedwith hour meters it may be necessar...

Page 45: ...justment No adjustment is necessary All engines are equipped with automatic tensioners that indicate when the drive belt isworn stretched A pointerand gauge are builtinto the tensioner Whenthe pointer...

Page 46: ...n Warning Be carefulwhen draining the oil is hot IDLER CONDITIONING 3 Remove and replace the drive belt Lift the drive belt LESSAIC tensioner and slide the drive belt under the drive belt POWER STEERI...

Page 47: ...cement REPLACEMENT OF ENGINETIMING BELT 2 3L ONLY Refer to Section B1 2 3L 3 8i4 0 3 4 REPLACEMENTOF ENGINE OIL FILTER 1 Place a drip pan under the oil filter 2 Unscrewthe oil filter 3 Useaclean ragto...

Page 48: ...e radiatorfiller neck 2 Verify thatthe coolantinthe reservoir is atthe COLD FILL mark Add coolant as necessary 4BUOAX 019 Coolant Quality 1 Verify that there is no buildup of rust or scale around the...

Page 49: ...LANT Warning Never removethe radiator cap vvhile the engine is hot Wrap a thick cloth around the cap when loosening it Use caution when draining hot coolant Caution Do not use alcohol or methanol base...

Page 50: ...4 If the ignition timing is not within specification check the crankshaft position sensor for damage Refer to Section G 5BUOF3 036 REPLACEMENTOF AIR CLEANER ELEMENT 1 Checkthe air cleaner elementfor e...

Page 51: ...s or clips 4BUOAX 030 REPLACEMENTOF SPARK PLUGS 1 When removingthe high tensionleads do notpulldirectly onthe lead Graspandtwistthe bootbackandforthonthe lead insulator to free the boot MG1037 B 7 2 W...

Page 52: ...the linings for wear or damage 3 Check the condition of the inner surface and the inner diameter of the drum Standard diameter Shown on drum Diameter limit Standard diameter 0 762mm 0 030 in REPLACEM...

Page 53: ...ONOF EXHAUST SYSTEM HEAT SHIELD 1 Visually check the exhaust system heat shield for damage 2 Replace it if necessary 4BUOAX 039 INSPECTION OF AIC SYSTEM Refer to 1997 B Series BETM 7BUOAX 008 INSPECTI...

Page 54: ...11 Inspectthe evaporative emission hose between the PCV valve and the charcoal canister and replace it if it is leaking INSPECTION OF BRAKE AND CLUTCH FLUID Check the fluid level in the reservoir The...

Page 55: ...4BUOAX 0 AIR VALVE Action Measure and adjust pressure Repair or replace suspension parts Reduce speed Rotate tires Overinflation Lack of rotation Incorrecttoe in Incorrectcamber or caster Malfunctioni...

Page 56: ...through one full revolution Runout limit mrn in TlRE ROTATION To prolongtire life andassure uniformtire wear rotatethe tires every 8 000 12 000 km 5 000 7 500 miles 4 TIRE ROTATION Radial direction t...

Page 57: ...d amount and type of oil through the oil level plug hole untilthe level reachesthe bottom of the oil level plug hole Fluid specification ATF MerconB or M I11 Capacity 2 65 liters 5 6 US pt 4 5 Imp pt...

Page 58: ...SMISSION FLUID 1 Loosenthe pan attachingbolts to drain the fluid from the transmission 2 When all the fluid has drained from the transmission remove and thoroughly clean the pan 3 Discardthe pan gaske...

Page 59: ...ug 2 Wipe the plugs clean 3 Apply sealant to the threads of the drain plug and filler plug 4 After the fluid has drained install the drain plug Tightening torque 19 30 N m 1 9 3 0 kgf m 15 20 ftelbf 5...

Page 60: ...MlNG BELT CYLINDER HEAD CYLINDER BLOCK EXTERNAL PARTS FRONT COVER CYLINDER BLOCK INTERNAL PARTS INSPECTION REPAIR B1 36 PREPARATION 81 36 CYLINDER HEAD B1 36 VALVE MECHANISM B1 36 CAMSHAFT B1 39 CYLIN...

Page 61: ...asket Replacement page 81 12 3 Hydraulic lash adjuster Removal Installation page 81 16 4 Front oil seal Replacement page I31 17 5BUOBi 002 5 Rear oil seal Replacement page B1 21 6 Engine Removal page...

Page 62: ...ficult starting PossibleCause Action p p p p p p p p p p p p p Malfunctionof engine relatedcomponents Burnt valve Replace Worn piston piston rings or cylinder Replace or repair Damagedcylinder head ga...

Page 63: ...tedparts Excessive maln bearlng 011 clearance Replace or repalr 81 49 M a n bearing se zed or heat damged B1 45 Excesslve crankshaft end play Replace or repair B1 50 Excess ve connecting rod bearlng 0...

Page 64: ...lnspection Coolant level engine cold Warning Never remove the radiator cap while the engine is hot Wrap a thick cloth around the cap when remov ing it 1 Verify that the coolant level is near the fill...

Page 65: ...tion and ambient temperature Check oil pressure If lower than specification check for cause Oil pressure 276 414 kPa 2 8 4 2 kgflcm2 40 40 psi 2 000 rpm Referto page BI 16 Press down HLA by hand If it...

Page 66: ...Fullydepressthe accelerator pedalandcrankthe engine 8 Note the maximum gauge reading 9 Check each cylinder as above MB1239 A Compression Lowest reading cylinder within 75 percent of the highest Refer...

Page 67: ...ection G in the 1997 B Series BETM 3 Remove the four A C compressor bolts and position the AIC compressor aside 4 Removethe A C compressor and power steering pump bracket bolts and position aside with...

Page 68: ...e as far clockwise as possible While holding tighten adjusting bolt to hold tensioner away from belt 5 Remove the timing belt Installation Note Timing belt 1 Loosen tensioner adjusting bolt 2 Using SS...

Page 69: ...e timing belt pulley with the TDC mark on the enginefront coverwiththecrankshaftkeypointingstraight UP Caution Always turn the engine in the direction of normal rotation clockwise asviewedfromthefront...

Page 70: ...leys 11 Loosen the belt tensioner adjustment bolt to allow the tensioner to move against the belt If the spring does not have enough tension to move the roller against the belt the belt hangs loose it...

Page 71: ...BETM 16 Disconnect the N C compressor 17 Removethe four AIC compressor bolts and position the A C compressor aside with the hoses attached 18 Remove the A C compressor and power steering pump mountin...

Page 72: ...anifold 1 Remove the exhaust manifold 2 Remove the exhaust manifold gasket I I MB1304 A 713UOB1 012 Installation Note Cylinder head 1 Clean all of the cylinder head gasket surfaces 2 Clean the cylinde...

Page 73: ...N m 7 1 kgf m 52 ft lbf Step 2 70 N m 7 1 kgf m 52 ftelbf Step 3 Turn all cylinder head bolts an additional 90 100 degrees in sequence Cylinder head cover 1 Clean the gasket surfaces of the cylinder h...

Page 74: ...19 28 ftalbf 5BUOB1 086 Front lifting eye lnstall the front lifting eye Tightening torque 20 30 N rn 2 1 3 0 kgf m 15 22 ft lbf 5BUOB1 015 Exhaust manifold Clean exhaust manifold bolts and or stud bol...

Page 75: ...in the reverse order of removal referring to lnstallation Note Removal Note Hydraulic lash adjuster 1 Rotate the camshaft so that the base circle of the cam is facing the applicable rocker arm 2 Colla...

Page 76: ...the four A C compressor bolts and position the A C compressor aside 4 Remove the AIC compressor and power steering pump mounting bracket bolts and position aside with the hoses attached 5 Remove the w...

Page 77: ...over I I MB1301 A 5BUOB1 022 Front oil seal Remove the front oil seal using the SSTs Installation Note Front oil seal Installthefrontoilseal usingCamandAuxiliary ShaftSeal Replacer T74P 6150 A or equi...

Page 78: ...the water pump pulley 6 Remove the crankshaft pulley 7 Remove the timing belt outer cover referring to Removal Note Refer to below 8 Remove the timing belt Refer to page B1 8 9 Remove the camshaft pu...

Page 79: ...OIL PUMP OIL SEAL Replacement 1 Remove the drive belt Refer to Section G 2 Recover the refrigerant from the A C system Refer to Section G in the 1997 B Series BETM 3 Remove the four AIC compressor bo...

Page 80: ...Installthe oil pumpoilseal usingCamandAuxiliary Shaft Seal Replacer T74P 6150 A or equivalent 5BUOB1 032 Timing belt outer cover Install the timing belt outer cover Tighteningtorque 8 12 N m 0 8 1 1 k...

Page 81: ...k Note Applya smallamountof cleanengineoilonthe new oil seal and the seal mating surface lnstall the new oil seal with the spring side toward L 1 MBI 038 c BUOBI 033 the engine I I Drive plate AT 1 ln...

Page 82: ...22 Remove the accelerator cable bracket with the accelerator cable attached and po ition aside 23 Disconnect the fuel charging wiring harness from the engine wiring harness 24 Remove the DPFE sensor f...

Page 83: ...o that they can be reinstalled in the cylinder from which they were removed 2 Clean the parts with steam blow off any remaining water with compressed air Note Duringthedisassemblyof any partor system...

Page 84: ...ifoldlthrottle body 5 Cylinder head cover assembly 6 Cylinder head cover gasket Removal Section F1 7 Lower intake manifold 2 Engine and generator wiring harnesses 8 Lower intake manifold gasket 3 High...

Page 85: ...NG BELT 1 Remove the water pump pulley 2 Disassemble in the order shown in the figure referringto Disassembly Note I I MB1311 A 5BUOB1 040 1 Crankshaft pulley 4 Timing belt pulley 2 Timing belt outer...

Page 86: ...break the SST 49 UNOl 067 when you attempt to relieve tension on belt 1 Loosen the timing belt spring pivot bolt Do not remove 2 Hold tensioner with SST 3 While holdingtensioner loosen adjustingbolt a...

Page 87: ...l seal Disassembly Note page B1 29 2 Camshaft thrust plate Disassembly Note page 61 29 3 Rocker arms not shown Disassembly Note page 81 29 4 Valve keepers Disassembly Note page 61 29 5 Upper spring se...

Page 88: ...BUOB1 043 Rocker arms Usingthe SST depress the valve springs and removethe rocker arms Note Remove the rocker arms from the HLA side Valve keepers Usingthe SST depress the valve springs and removethe...

Page 89: ...Refer to page 81 31 3 Disassemble in the order shown in the figure referringto Disassembly Note MB1314 B 5BUOB1 047 1 Rear cover plate 5 Oil pan 2 Water pump Disassembly Note page B1 32 Disassembly N...

Page 90: ...and flywheel MT 1 Remove the bolts and clutch cover 2 Removethe clutch disc Drive plate AT Remove the six bolts the reinforcement plate and the drive plate I I MB1203 B 5BUOB1 049 Water pump Remove th...

Page 91: ...e the bolts and the engine oil pan 2 Remove the gasket Clean the engine and the oil pan gasket surfaces Oil pump strainer and tube 1 Removethe nutandthetwo boltsandremovethe oilpump strainer and tube...

Page 92: ...inner timing belt cover 7 Remove the front oil seal referring to Disassembly Note Refer to below 8 Disassemble in the order shown in the figure referring to DisassemblyNote I MB1315 A 6BUOB1 014 1 Fr...

Page 93: ...Inspection page B1 43 5 Connecting rod Disassembly Note page B1 35 Inspection page B1 43 I 5BUOB1 053 6 Piston Inspection page B1 41 7 Main bearing caps Disassembly Note page B1 35 8 Main bearing and...

Page 94: ...shaft journals or the cylin der walls 3 Use the handle of a hammer to push the piston and connecting rod assembly through the top of the cylinder I T 5BUOB1 103 Piston ring Caution Do not apply excess...

Page 95: ...Repair or replace as necessary 1 Sinking of valve seat 2 Damage of manifold contact surface 3 Camshaft oil clearance and end play 3 Ifdistortionexceedsspecification grindthecylinder head I MB1215 A Di...

Page 96: ...ator with a flat end indicator point 1 Installthe tool on the valve stem n t i l it is fully seated and tighten the knurled setscrew firmly Permit the valve to drop away from its seat until the tool c...

Page 97: ...ue does not appear 360 around the valve face replacethe valve 2 If blue does not appear 360 around the valve seat resurfacethe seat 5 Check the valve seat runout with a valve seat runout gauge as illu...

Page 98: ...n not be cleaned replace the camshaft 3 Set camshaft on V blocks and measure the runout Runout 0 127mm 0 005 in max 4 Inspect the camshaft for wear and damage Replacethe camshaft if necessary MB1218 A...

Page 99: ...checkingthe camshaft end play adjust the valve clearance 1 Pushthe camshaft toward the rear of engine Installa dial indicator so the indicator point is on the camshaft gear 2 Zero the dial indicator...

Page 100: ...UOBI 018 Limit 0 127mm 0 005 in PISTON PISTON RING AND PISTON PIN Piston 1 Inspectthe outer circumferences of all pistons for seizing and scoring Replace as necessary 2 Measure outer diameter of each...

Page 101: ...0016 4 0033 in Oil Ring Snug fit Service Limit 0 15mm 0 006 in max 2 If the clearance exceeds the maximum replace the MB1029 A piston 3 Inspect the piston ring for damage abnormal wear or breakage Re...

Page 102: ...0 005 0 01 0mm 0 0002 0 00014 in 4 If the clearance exceedsspecification replacethe piston and or piston pin 5 Measure each piston pin length Length 62 3 70 1 mm 2 73 2 76 in 6 If the length exceeds s...

Page 103: ...ng bore out of roundand taper Out of round 0 01mm 0 0004 in Taper 0 01mm 0 0004 in 6 If the out of round or taper measurements exceed the maximum replace the connecting rod CRANKSHAFT 1 Check the jour...

Page 104: ...m 0 002 in main journal and crankpin Main journal diameter undersize rnm in Bearing size Journal diameter 0 050 10 0021 k5 97 55 95 12 2039 2 2031 I Crankpin journal diameter undersi2 e rnrn in1 Beari...

Page 105: ...eplace as necessary 4BUOB1 108 FLYWHEEL MT I Inspect the flywheel for cracks heat check or other damage that would make it unfit for further use 2 Acceptable flywheels may be repaired by polishing wit...

Page 106: ...pin press fitdiameter must not extend above the new surface 5 The clutch cover retaining bolts must screw into the flywheel under handtorque to within 1 52mm 0 06 in of new surface 6 Flywheels with di...

Page 107: ...st bearing lower 4 Main bearing caps 5 Rear oil seal Assembly Note page B1 50 6 Pistons Assembly Note page B1 51 STEP 1 Tighten all bolts by hand until STEP 2 66 41 6 9 8 1 50 59 STEP 3 102 115 I0 4 1...

Page 108: ...m 6 9 8 2 kgf m 50 60 ft lbf Retighten to 102 1 15 N m 10 4 1 1 7 kgf m 75 85 ft lbf 9 Remove the main bearing cap 10 Measurethe Plastigageat eachjournal at the widest point for the smallest clearance...

Page 109: ...thrust bearing Rear oil seal 1 Lubricate rear oil seal and mating surface with clean engine oil before installation 2 Install the rear main oil seal using the SST Caution The rear face of the seal mu...

Page 110: ...stons connecting rods bearings and con necting rod bearing caps must be installed in the original locationfrom which they were removed 1 Oil all pistons piston rings and cylinder walls before installa...

Page 111: ...for the smaller clearance and the narrowest point for the largest clearance Oil clearance Number One Main Bearing Standard 0 010 0 054mm 0 0004 0 0021 in Maximum 0 054 0 0021 in Number Two to Five Mai...

Page 112: ...o Assembly Note L MB1323 A 5BUOB1 066 1 Front cover gasket 2 Front cover Assembly Note below Front cover Note Beforefinally adjusting the cover into positionand tightening attaching bolts usethe SST t...

Page 113: ...efer to 81 57 3 Install the drive plate AT referring to Assembly Note Refer to B1 57 N m kgf m ft lbf MB1321 B 5BUOB1 060 1 Oil pump strainer and tube not shown 4 Oil filter and oil filter mounting in...

Page 114: ...l pan I Apply sealant in six places at joints between the front cover and the cylinder block and rear main bearing cap and engine block as shown in figure 2 Install a new oil pan gasket to the engine...

Page 115: ...sing a feeler gauge Repeatthe procedure for the other mountingpad Select spacers of the required thickness from the chart Caution Failure to measure the required spacer thickness can result in insuffi...

Page 116: ...alcohol base solvent so thatthe surfaces are free from any oil film Note Do not use cleanerswith a petroleum base Do not immersethe clutch cover in solvent 4 Position the clutch disc on flywheel so Cl...

Page 117: ...eals Assembly Note page B1 59 4 Camshaft bearings Assembly Note page B1 60 5 Camshaft Assembly Note page I31 60 6 Camshaft thrust plate Assembly Note page 61 61 7 Camshaft oil seal Assembly Note page...

Page 118: ...otector plasticinstallationcap supplied with valve seals over end of valve 2 Start valve seal carefully over valve seal protector Push valve seal down until jacket touches top of valve guide 3 Remove...

Page 119: ...the recommendeddimension Do not install spacers unless necessary Use of spacers in excess of recommendations will result inoverstressing the valve springs andoverloading thecamshaftlobes Thiscould lea...

Page 120: ...t 4BUOB1 139 Cylinder head 1 Clean all cylirider head gasket surfa ces 2 Clean all lower intake manifold gasket surfaces 3 Clean all exhaust manifoldgasket surfaces 4 Blow the oil out of the cylinder...

Page 121: ...1 Camshaft pulley Assembly Note page B1 63 2 Timing belt tensioner Assembly Note page B1 63 3 Oil pump pulley 4 Timing belt pulley N m kgfm ft4bf 5BUOB1 072 5 Timing belt Assembly Note page B1 9 6 Tim...

Page 122: ...ent bolt and spring bolt Tightening torque Adjustment bolt 35 45 N m 3 5 4 5 kgf m 25 33 ftelbf Spring bolt 40 55 N m 4 2 5 5 kgf m 3 0 4 0 ftellbf I 2 MB1003 A 5BUOB1 098 Timing belt outer cover lnst...

Page 123: ...5 Assembly Note page 81 66 2 Lower intake manifoldgasket 6 Spark plugs 3 Lower intake manifold 7 High tensionlead wires Assembly Note page 81 65 8 Engine and generator wiring harness 4 Cylinder head c...

Page 124: ...0 kgfem 15 22 ftslbf Step 2 60 40 N m 6 1 4 1 kgf m 45 59 ft lbf 0 FRONT OF ENGINE MB1331 A 5EIUOB1 077 I I MB1330 B 5BUOB1 076 Lower intake manifold 1 Install the lower intake manifold 2 Install fou...

Page 125: ...ad cover and cylinder head 2 Install the cylinder head cover gasket 3 Install the cylinder head cover Tightening torque 9 13 N m 0 9 1 3 kgf cm 80 1 15 inslbf Dipstick tube and bracket Install the dip...

Page 126: ...ot enter the clutch disc If the engine hangs up after the shaft enters turnthecrankshaft inthe clockwisedirectionslowly trans mission in gear until the shaft splines mesh with the clutch disc splines...

Page 127: ...Converter inspection plate 2 5 3 6 N m 24 36 kgf cm 22 1 31 8 in lbf 11 Connect the ground cable to the engine 12 Connectthe fuel supply and return linesto the two fuel rail fittings Tightening torqu...

Page 128: ...16 21 ft lbf 18 Install the air conditioning compressor to the mounting bracket if equipped Tightening torque 22 28 N rn 2 3 2 9 kgfem 16 21 ftelbf A 41 54 t4 1 5 5 19 Connect the air conditioning hos...

Page 129: ...to the upper intake manifold Tightening torque 21 28 N m 2 1 2 8 kgfem 16 21 ft lbf 24 Connect the accelerator cable to the throttle body 25 Install the generator bracket I MB1333 A Tightening torque...

Page 130: ...r cleaner outlet tube to the throttle body 38 Connect the Mass Air Flow MAF and Intake Air Tem perature IAC sensors 39 Install the hood and align 40 Connect fuel pump inertia switch connector Steps Af...

Page 131: ...2 23 TIMING CHAIN 82 26 CYLINDER HEAD B2 29 CYLINDER BLOCK EXTERNAL PARTS B2 30 CYLINDER BLOCK INTERNAL PARTS B2 32 INSPECTION1 REPAIR B2 36 PREPARATION B2 36 CYLINDER HEAD B2 36 VALVE MECHANISM B2 37...

Page 132: ...placement page B2 19 Assembly page B2 60 6 Engine 2 Cylinder head gasket Removal page B2 21 Replacement page B2 8 Disassembly page B2 23 3 Tappet InspectionIRepair page B2 36 Removal lnstallation page...

Page 133: ...ond fuel system Refer to Section FT Malfunctionof ignitionsystem Refer to Section G Poor idling Malfunctionof engine related components Poor valve to valveseat contact Replaceor repair 62 38 Damaged c...

Page 134: ...ce I Malfunction of fuel system j Refer to Section FT I Malfunction of ignitionsystem 1 Refer to Section G Crankshaft or bearing relatedparts Excessive main bearing oil clearance Mainbearingseized or...

Page 135: ...ile the engine is hot Wrap a thick cloth around the cap when removing it When removing the radiator cap loosen it slowly until the pressure in the radiator is released and then remove it 1 Verify that...

Page 136: ...ointer andgaugeare builtintothetensioner Whenthe pointer no longer registers within the range limits of the gauge the belt must be replaced Refer to Section G IGNITIONTIMING IDLE SPEED Initial Timing...

Page 137: ...ch cylinder as above Compression Lowest reading cylinder is within 75 percent of the highest Refer to Section T D 9 If the compression in one more cylinders is low pour a small amount of engine oil in...

Page 138: ...heater water hoses and move them out of the way 8 Remove the ignition coil referringto Removal Note Refer to page 82 9 9 Remove the upper intake manifold Refer to Section F2 10 Remove the drive belt 1...

Page 139: ...vethe fuel linebracketboltfrom the front of cylinder head L I MB1280 B 5 0 2 0 0 9 6 Remove the PCV valve 7 Remove the fuel injector harness stand offs from the inboard cylinder head cover studs and m...

Page 140: ...be removed to allow removal of the lower intake manifold Rocker arms 2 Remove the push rods Note Identify the position of each rod The rods must b installed in their original location when reass embl...

Page 141: ...r block using the dowels for alignment Make sure the gasket is aligned as shown in the figure Note Replacethe alignment dowels if they aredamaged 3 Carefully position the cylinder head s on the cylind...

Page 142: ...ause gasket leaks Always use care when scrap ing aluminum gasket surfaces 3 If installing a new lower intake manifold transfer the fuel injectors fuel supply manifold engine coolant tempera ture senso...

Page 143: ...quence using a two step process Tighten in numerical sequence Tightening torques Step 1 15 N m 1 5 kgf m 11 ftelbf Step 2 26 32 N m 2 6 3 2 kg m 19 24 ft lbf 8 Connect the heater hoses 9 Connect the u...

Page 144: ...ed in the cylinder headand the push rods must befully seated in the rocker arm sockets and tappets before final tight ening Note Camshaft positions A and B are required to placethe tappet assembly on...

Page 145: ...use a straight down approach to align the holes Once the cover comes in contact with the RTV sealer any adjustment for bolt alignment can roll the gasket from the cover channel resulting in leaks Tigh...

Page 146: ...vels TAPPET Removal 1 Installation Warning Release the fuel pressure Refer to Section F2 Keep sparks and open flame away from fuel area 1 Disconnect the negative battery cable 2 Drain the cooling syst...

Page 147: ...low removal of the intake manifold 2 Remove the push rod 4811082 046 Tappets FRONT OF ENGINE 1 Loosen the tappet guide plate bolts 0 2 Remove the guide plate retainer assembly 3 Removethe tappet guide...

Page 148: ...amper referringto Removal Note Refer to below 5 Remove the front oil seal referringto Removal Note Refer to below 6 Install in the reverse order of removal referringto Installation Note 0 FRONT OF ENG...

Page 149: ...er sealing surface with clean engine oil 2 Apply sealer to the keyway on the damper prior to instal lation 3 Install the damper using Damper arid Front Cover Seal Installer T82L 6316 A or equivalent 4...

Page 150: ...prior to removal of seal Using a sharp awl punch one hole into the rear oil seal metal surface between the lip and block Screw in the threaded end of Jet Plug Remover T77L 9533 B or equivalent and rem...

Page 151: ...assembly Refer to Section F2 6 Disconnect the upper and lower hoses from the radiator 7 Remove the radiator and fan shroud Refer to Section E2 8 Remove the generator and bracket Positionthe generator...

Page 152: ...ower the vehicle 31 Attach an engine lift to the engine 32 Position a jack under the transmission 33 Raise the engine slightly and carefully pull it from the transmission Caution Do not damage the rea...

Page 153: ...y were removed 2 Clean the parts by using a steam cleaner Blow dry with compressed air Note Duringdisassemblyof anypartof the system besureto study itsorderof assembly Also note any deformation wear o...

Page 154: ...ick tube and bracket not shown 4 Cylinder head cover 2 Ignition coil Disassembly Note page B2 25 3 Upper intake manifoldlthrottle body 5 Lower intake manifold assembly Disassembly Note page B2 25 Remo...

Page 155: ...The cylinder head cover incorporates an integral gasket which should last the life of the vehicle 4BUOB2 075 Lower intake manifold 1 Mark the location of vacuum lines and remove them 2 Disconnect the...

Page 156: ...tioning 7 Removethe air conditionercompressor bracket automatictransmission vehicles with air conditioning 8 Remove the oil pan referring to Disassembly Note Refer to page B2 27 9 Remove the timing co...

Page 157: ...rlear oil pan seals Timing cover 1 Remove the timing cover bolts 2 Remove the timing cover Note To remove the timing cover without removing the water pump donotremoveboltsmarked11through 15 as shown 3...

Page 158: ...enter TDC andthetiming marksarealigned as shown 2 Check the timing chain for deflection and for excessive wear TIMING MARKS MUST 3 Remove the camshaft pulley bolt BE IN POSITION SHOWN WITH NO 1 PISTON...

Page 159: ...spection page B2 36 Inspection page 82 39 2 Valve keepers 5 Valves Disassembly Note below lrispection page B2 37 3 Valve spring seats 6 Valve seals Disassembly Note page B2 30 Disassembly Note Rocker...

Page 160: ...LINDER BLOCK EXTERNAL PARTS 1 Remove the clutch cover and the clutch disc MT Refer to Section H 2 Remove the flywheel MT referring to Disassembly Note Refer to below 3 Remove the drive plate AT referr...

Page 161: ...DISASSEMBLY 1Oil pump FRONT OF ENGINE MB1147 A 4EiUOB2 091 1 demoie the oil pump assembly bolt 2 Remove the oil pump assembly and the intermediate shaft...

Page 162: ...DISASSEMBLY CYLINDER BLOCK INTERNAL PARTS 1 Remove the tappets referring to Disassembly Note Refer to page B2 33 2 Disassemblein the order shown in the figure referring to Disassembly Note...

Page 163: ...B2 45 page B2 46 Disassembly Note Tappets 1 Loosen the tappet guide plate bolts 2 Remove the guide plate retainer assembly 3 Removethetappet guide platesfrorri the tappets by lifting straight up 4 Re...

Page 164: ...ld the end of the puller screw to prevent it from turning 6 Repeat steps 4 and 5 for each bearing To remove the front bearing install the puller from the rear of the block Connecting rod cap Before re...

Page 165: ...nal and removethe upper bearing 7 Pushthe piston and the connecting rod up and out of the bore by tapping with the wooden end of a hammer or 1 1 7 8 A 6 3 0 2 0 1 0 similar tool while guiding the conn...

Page 166: ...cratchedor damaged by contact with the cylinder block 4BUOB2 101 INSPECTION REPAIR PREPARATION 1 Cleanall parts beingsureto removeallgasketfragments dirt oil etc 2 Performthe inspectionsandrepairsinth...

Page 167: ...still out of specification replace the cylinder head 8 STEM TIP VALVE MECHANISM Valve and Valve Guide 1 Inspect each valve for the following and replace or resurface as necessary 1 Damaged or bent ste...

Page 168: ...y Permit the valve to drop away from its seat untilthe tool contacts the upper surface of the valve guide 2 Position the dial indicator with its flat tip against the centerportionof thetool sspherical...

Page 169: ...lengths Weak valve springs cause poor engine performance Replaceany spring nol within specification Pressurellength Loaded 800 6 N 180 Ibs at 29 5mm 1 16 in Unloaded 288 1 N 65 Ibs at 48 lmm 1 58 in 3...

Page 170: ...journal diameter and the bore diameter Subtract the journal diameter from the bore diameter to determine the 31282 A 4 0 6 2 1 0 7 oil clearance 1 0 2 4 A Minimum 6 477mm 0 255 in Oil clearance 0 025...

Page 171: ...arance by measuringthe tappet bore diameter and subtracting the tappet diameter from the bore diameter Tappet oil clearance Standard 0 018 0 069mm 0 0007 0 0027 in Limit 0 127mm 0 005 in 7 Measure the...

Page 172: ...f round Standard 0 025mm 0 001 in Maximum 0 05mm 0 002 in 1 I MB1027 A 4BUOB2 109 PISTONS PISTON RINGS AND PISTON PINS Pistons 1 Inspectthe outer circumferences of all pistons for seizing and scoring...

Page 173: ...ng Clearance Top 0 0404 095mm 0 0016 0 0037 in Bottom 0 0404 095mm 0 0016 0 0037 in Oil Ring Snug fit Service Limit 0 15mm 0 006 in maximum 2 If the clearance exceeds the maxi mum replace the MBI 029...

Page 174: ...pin 5 Measure the piston pin length Length 76 5 77 2mm 3 012 3 039 in 6 If the length exceeds specifications replace the piston pin CONNECTING RODS 1 Measure the small end inner bore diameter of each...

Page 175: ...e scoring and oil hole clogging 2 Set the crankshaft on V blocks 3 Measurethe crankshaft runout Replacethe crankshaft if necessary Runout 0 05mm 0 002 in 4 Measure each journal diameter in the X and Y...

Page 176: ...mage PULLEYS Camshaft Pulley and Crankshaft Pulley lnspectthe teeth of each pulleyfor wear deformationand other damage replace as necessary 4BUOB2 116 TIMING CHAIN OUTER COVER lnspect the outer cover...

Page 177: ...ASSEMBLY CYLINDER BLOCK INTERNAL PARTS 1 Assemble in the order shown in the figure referringto Assembly Note 2 Installthe tappets referringto Assembly Note Refer to page B2 54...

Page 178: ...learances as described below Oil clearance inspection 1 Remove any foreign material and oil from the jour nals and bearings 2 Install the upper main bearings 3 Installthe lower main bearings intothe m...

Page 179: ...4 Install the main bearing caps Note Install the main bearing caps in their original positions 5 Prythecrankshaftforward againstthethrustsurfaceof the upper half of the bearing 6 Hold the crankshaft c...

Page 180: ...Piston rings Install the piston rings to the piston using a piston ring expander Note Never install the piston rings with hands Piston rings should be staggered on the piston to makesurethe pistonring...

Page 181: ...dome notch and the button on the connecting rod face the front of engine 9 Installa pistonby tapping with a wooden hammer handle or similar device while aligning the connecting rod to the crankshaftj...

Page 182: ...clean engine oil to the connecting rod bearings 3 Installthe bearing in the connecting rod and cap with the tangs fitting in the slots provided 4 Turn the crankshaft throw to the bottom of its stroke...

Page 183: ...ess them inplacewith Camshaft BearingSet T65L 6250 A or equivalent Be sure to center the p lling plate and puller screw to avoid damage to the bearing Caution Failure to use the correct exlpanding col...

Page 184: ...ate with clean engine oil and install the two bolts Tightening torque 8 1 2 N m 0 8 1 2 kgfem 6 8 ft lbf 3 lnstall the guide plate retainer assembly A81 146 8 5BUOB2 047 Tappets GUIDE PLATE RETAINER 1...

Page 185: ...plate AT Installthe drive plate and reinforcement plate and install the bolts usirig the standard cross tighteningsequence Tightening torque 73 47 N m 7 3 4 7 kgf m 541 64 ftelbf Flywheel MT Installt...

Page 186: ...at Assembly Note below Assembly Note page B2 57 2 Valve seals 5 Valve keepers Assembly Note page B2 57 Assembly Note page 82 57 3 Valve springs 6 Cylinder head Assembly Note page B2 57 Assembly Note p...

Page 187: ...de of the valve keepers with dividers Check the dividers against the scale If the assembled height is greater than specifica tion installnecessary0 762mm 0 030 in thickspacer s between the cylinder he...

Page 188: ...basecircle of the camshaft lobe to check the collapsed tappet gap I I MI31134 A Tappet gap 2 234 77mm 0 088 0 189 in FULCRUMAND BOLT MUST BE FULLY SEATED AFTER FINALTORQUE Refer to the chart for whic...

Page 189: ...nstall the new bolts and hand tighten MB1126 A 5 Tighten the bolts in sequence as shown in the figure FRONT OF ENGINE Q Tightening torque 80 N m 8 1 kgf m 59 ft lbf 6 Back off all of the bolts a minim...

Page 190: ...to Assembly Note Refer to page 82 62 5BUOB2 079 TIMING MARKS MUST BE IN POSITION SHOWN WITH NO 1 PlSTONAT TDC FIRING I FRONT OF ENGINE Assembly Note Timing chain 1 Clean and inspect all parts before i...

Page 191: ...figure 5 Tighten bolts to specification Tightening torques A 20 30 N m 2 0 3 0 kgf m 115 22 ft lbf 6 8 1 2 N m 0 8 1 2 kgf m 6 4ft lbf Oil pan 1 Lightly oil all bolt threads before instisllation 2 Cle...

Page 192: ...to specification Tightening torque 10 14 N m 1 O 1 4 kgf m 7 10 ft lbf Damper 1 Coat the damper sealing surface with clean engine oil 2 Apply sealant to the keyway of the damper prior to installation...

Page 193: ...9 24 REPLACE 2 0 2 0 3 0 I I MB1175 C 5BUOB2 058 1 Exhaust manifolds 4 Upper intake manifold throttle body assembly Assembly Note page B2 64 Iristallation Section F2 2 Lower intake manifold 5 Ignition...

Page 194: ...the tappet valley to catch any gasket material After scraping carefully lift the cloth from the tappet valley preventing any particles from entering the oil drain holes or the cylinder head Use a suit...

Page 195: ...the cylinder head Usecare to prevent disturbing the rubber sealer which can cause sealing voids Install bolts 1 2 3 anti 4 and handtighten Installthe remaining bolts and tighten in sequence using a tw...

Page 196: ...N m 3 54 5 kg m 26 47 ft ft 5BUOB2 080 INSTALLATION PROCEDURE 1 Lower the engine carefully into the engine compartment referring to lnstallationNote Refer to page B2 67 2 Raise the vehicle and secure...

Page 197: ...necessaryto adjustthe positionof the transmissionin relationto the engine if the primary shaft will not enter the clutch disc If the engine hangs up after the shaft enters turn the crankshaft slowly w...

Page 198: ...158 Fan shroud Install the fan shroud Tightening torque 5 5 4 N m 56 41 kgf cm 48 70 in lbf 4BUOB2 159 Steps After Installation 1 Fill the radiator with the specified amount and type of engine coolant...

Page 199: ...EPLACEMENT REMOVAL PROCEDURE DISASSEMBLY PREPARATION AUXILIARY PARTS 83 30 CYLINDER BLOCK EXTERNAL PARTS B3 32 TIMING CHAIN B3 34 CYLINDER HEAD B3 35 CYLINDER BLOCK INTERNAL PARTS B3 37 INSPECTION REP...

Page 200: ...B3 INDEX INDEX COMPRESSION PRESSURE INSPECTION PAGE 83 8...

Page 201: ...il seal Replacement page B3 26 4 Front oil seal Replacement page B3 25 5 Cylinder head cover gasket Removal page B3 14 Installation page B3 16 6 Rocker arm assembly Removal Installation page B3 19 7 E...

Page 202: ...ed rPm Ignition timing Initial timing BTDC Firina order Difficult starting not adjustable 8 12 I0 k 2 not adjustable 14 2 5 3 6 Poor idling Excessive oil consumption PossibleCause Malfunctionof engine...

Page 203: ...r to Section P Wrong size tires Refer to Section Q Excessive connecting rod bearing oil clearance Replace or repair B3 53 Connecting rod bearing seized or L __ 83 48 Piston related parts Worn cylinder...

Page 204: ...hed 4 0 3 0 0 8 part of the oil dipstick ENGINE COOLANT lnspection Coolant level engine cold Warning Never remove the radiator cap while the engine is hot Wrap a thick cloth around the cap when removi...

Page 205: ...wear cracksandfraying Replace if necessary 2 Verify the drive belt is correctly mounted on the pulleys Adjustment No adjustment is necessary The 4 OL engine is equipped with an automatic tensioner tha...

Page 206: ...Initial Timing Note Initialtiming is preset and is not adjustable Initial timing can be checked Refer to Section G Ignitiontiming 8 12 10k2 BTDC Refer to Section G ldle speed Note ldle speed is prese...

Page 207: ...Check each cylinder as above Compression Lowest reading cylinder is within 75 percent of the highest Refer to Section TD 9 If the compression in one or more cylinders is low pour a small amount of cle...

Page 208: ...r head perform the following 1 Remove the AIC compressor if equipped 2 Remove the power steering oil pump and bracket 8 If removing the right cylinder head perform the following 1 Remove the generator...

Page 209: ...the new cylinder headbolts inthe order shown in the figure Tighteningtorque 30 35 N rn 3 0 3 5 kgfam 22 26 ft lbf 2 Apply sealant to the cylinder head rnating surfaces as shown in the figure Note The...

Page 210: ...6 1 1 ft lbf 8 Tighten the new cylinder head bolts an additional 90 in the order shown in the figure 9 Tighten the lower intake manifold bolts and nuts Tightening torque 15 22 N m 1 5 2 2 kgfsm 11 16...

Page 211: ...Disconnect the negative battery cable 2 Remove the cylinder head gaskets Refer to page B3 10 3 Remove the tappets referring to Removal Note Refer to below 4 Install in the reverse order of removal re...

Page 212: ...iring harnessfrom clip referringto Removal Note Refer to page 63 15 6 Remove the right cylinder head cover bolts reinforcementplates 7 If removingthe left cylinder head cover perform the following 1 R...

Page 213: ...lts and shield I MB1356 A 513UOB3 009 Air intake hose 1 Loosen the clamps 2 Remove the breather hose 3 Remove the air intake hose Filler neck vacuum hose Pull the coupling to remove the filler neck va...

Page 214: ...linder headcover bolts referringto lnstallation Note Referto page B3 17 3 Positionthe fuel hoses correctly and install the fuel hose clip bolt 4 Fasten the left wiring harness to the clip referringto...

Page 215: ...n G 3 Installthe high tension leads onto the cylinder head covers 4 lnstall the air conditioning pipe bolt onto the upper intake manifold if equipped 5 lnstall the air intake hose referringto lnstalla...

Page 216: ...A C compressor Install the AIC compressor to the bracket Tightening torque 24 30 N m 2 5 3 1 kgfam 18 23 ftelbf 4BUOB3 036 Right wire harness Installthe wire harness and push down on the clip Filler n...

Page 217: ...Removall lnstallation 1 Remove the cylinder head cover gaskets Refer to page U3 14 2 Remove in the order shown in the figure referring to Removal Note 3 lnstall in the reverse order of removal referr...

Page 218: ...11083 044 Rocker arm shaft bolts Caution The bolts should betightened gradually two turns at a time Tightening torque 32 N m 3 3kgf m 24 ft lbf 90 degrees Note Apply clean engine oil to the rocker arm...

Page 219: ...over referring to Removal Note Refer to page 83 22 8 Install in the reverse order of removal referring to InstallationNote Removal Note Fan assembly 1 Hold the water pump pulley with the SST Loosen th...

Page 220: ...bolts and studs as shown Tightening torque 17 21 N m 1 8 2 0 kgfem 13 1 5 ftdbf Bolt length Bolt A M8 x 47 Bolt B M8 x 25 I I MBIO A 48 083 052 Stud C M8 x 25 I 1 Crankshaft position sensor 1 Install...

Page 221: ...utch assembly 2 Hold the water pump pulley with the SST Tighten the clutch assembly with the SST Tightening torque 40 1 35 N m 4 1 1 3 8 kgf m 30 1 00 ft lbf Note The clutch assembly has left hand thr...

Page 222: ...Refer to page 83 25 4 Remove the timing chain pulley key 5 Remove in the order shown referring to Removal Note 6 Install in the reverse order of removal referring to lnstallation Note 1 Camshaft pull...

Page 223: ...tall the camshaft pulley timing chain and timing chain pulley as an assembly Note The tensianer side of the timing chain is held inward and the guide side shoi ld be tight 3 Install the camshaft pulle...

Page 224: ...l pilot seal replacer k4 For installationof crankshaft rear oil seal 5811083 017 REPLACEMENT 1 Disconnect the negative battery cable 2 Remove the engine assembly Refer to page 83 27 3 Cut the rear oil...

Page 225: ...Removal Note Refer to page B3 29 16 Disconnectthe following harness connectors 1 Ignition coil pack 2 Oil pressure sensor 3 Engine coolant temperature sensor 4 Injectors 5 Intake air temperature senso...

Page 226: ...oil pump 1 Remove the power steering oil pump bolts 2 Remove the power steering oil pump with the hoses still attached 3 Position the power steering oil pump away from the engine and secure it with wi...

Page 227: ...uts DISASSEMBLY PREPARATION SST 413UOB3 074 Torque converter nuts AT only Access the torque converter nuts through the starter mounting opening 4BUOB3 075 Fan clutch holding tool 49 UNOI 008 Fan clutc...

Page 228: ...efer to below 4 Remove the upper intake manifold referringto Disassembly Note Refer to below 5 Remove the fuel supply manifold referringto Disassembly Note Refer to page B3 31 6 Remove the lower intak...

Page 229: ...ke manifold nuts and bolts 2 Remove the lower intake manifold and gasket Fan assembly 1 Hold the water pump pulley with tlie SST Loosen the clutch assembly with the SST Note The clutch assembly has le...

Page 230: ...referringto Disassembly Note Referto below 3 Remove the baffle referringto Disassembly Note Referto page B3 33 4 Remove the water pump referringto Disassembly Note Refer to page B3 33 5 Remove the cra...

Page 231: ...or 1 Remove the screws 2 Remove the crankshaft position sensor Crankshaft pulley Remove the crankshaft pulley using the SST Note SST Number 49 UNO1 001 Crankshaft Damper Remover 4BUOB3 093 413UOB3 092...

Page 232: ...bly Note I MB1079 A I 4811083 095 1 Camshaft pulley 3 Timing chain pulley Disassembly Note below Disassembly Note below 2 Timing chain 4 Timing chain auto tensioner Disassembly Note below 5 Guide Disa...

Page 233: ...page B3 36 3 Disassemble in the order shown in the figure referring to Disassembly Note VALVE SEAL REPLACE I 1 ME1080 A 5811083 046 1 Cylinder head 6 Valve 2 Gasket 7 Valve seal 3 Valve keeper isassem...

Page 234: ...he position of each push rodfor installation Valve keeper valve spring seat and valve spring 1 Assemble Valve Spring Compressor T86L 6565 A or equivalent and Valve Spring Compressor Bar T74P 6565 B or...

Page 235: ...DISASSEMBLY B3 CYLINDER BLOCK INTERNAL PARTS Disassemble in the order shown in the figure referring to Disassembly Note...

Page 236: ...B3 39 Inspection page B3 43 13 Thrust plate Disassembly Note Connectingrod cap Before removing the connecting rod caps measure the connecting rod side clearance Refer to page B3 54 ME1082 6 6BUOB3 01...

Page 237: ...que Ifthe large end does notdrop by its own weight replace the pistori or the piston pin 2 Assemble Piston Pin Tool D81L 6 135 A or equivalent into the piston pin as shown Caution Verify that PistonPi...

Page 238: ...he six directions shown in figure Distortion Maximum 0 07mm 0 003 in per 152mm 6 0 in Note Before grinding the cylinder head check the fol lowing Repair or replace as necessary dB1015 A 1 Sinking of v...

Page 239: ...7 A 2 Measure the valve stem diameter and replacethe valve if necessary Diameter Standard IN 8 02 8 04mm 0 315 9 4 3 167 in EX 8 004 01mm 0 3149 0 3 1 56 in Oversize4 20mm 0 008 in IN 8 23 8 24mm 0 32...

Page 240: ...um installanoversize stem valve and ream the guide 4BUOB3 Ill Valve Seat 1 Inspect the contact surface of the valve seat and valve face for the following I Roughness 2 Damage 2 If necessary resurfacet...

Page 241: ...th Free length 48 5mm 1 91 in approximate 4 Check the out of squareof the valve spring Out of square 1 98mm 0 078 in Caution Make sure the springs are reassembled to their original dampers MB1023 B 4B...

Page 242: ...n surfaces for wear and damage Replace the tappet if necessary 6BUOB3 008 I I MB1089 B 4811083 I14 CYLINDER BLOCK 1 Check the cylinder block for the following and repair as necessary 1 Leakage damage...

Page 243: ...0 0381mm 0 0015 in Maximum 0 127mm 0 005 in MB1027 A I 4ELUOB3 115 PISTON PISTON RING AND PISTON PIN Piston 1 Inspectthe outer circumferencesof all pistonsfor seizing and scoring Replace as necessary...

Page 244: ...ace the pis ton 3 Inspect the piston ring for damage abnormal wear or breakage Replace as necessary 4 Insert piston ring into cylinder by hand and use the piston to push it to the bottom of the ring t...

Page 245: ...94324 9439 in Caution If the connecting rod is replaced the connecting rodcapand bolts mustalso bereplaced sincethey are a matched set 2 Check the bend arid twist factor of the connecting rod Repair o...

Page 246: ...T INTO BEARING MATERIAL SCRATCHED BY DIRT LACK OF OIL OR IMPROPER CLEARANCE FROM EDGES RADIUS RIDE HOURGLASSING RADIUS RlDE Undersize bearing 0 0254mm 0 001 in BEARING Main Bearing and Connecting Rod...

Page 247: ...ankshaft damper replacer 49 UNOl 007 Fan clutch holding tool installing seals For installing crankshaft pulley For removal1 installation of fan 1 Clean all parts before installation 2 Apply clean engi...

Page 248: ...ASSEMBLY CYLINDER BLOCK INTERNAL PARTS Assemble in the order shown in the figure referring to Assembly Note...

Page 249: ...all the upper main bearing with the tang in the slot 3 lnstallthe lower main bearingsintothe main bearing caps 4 Installthe crankshaft into the c ylinder block 5 Position Plastigage atop the journals...

Page 250: ...n Verify that the piston pin tool is fit squarely into the piston before pressing 2 Apply clean engine oil to the piston pin 3 Press the piston pin into the piston and connecting rod Piston ring 4BUOB...

Page 251: ...semblies into the cylinder block with the indent on the top of the piston facing the front of the engine Use a piston installer tool commercially avail able to install 4BUOB3 131 Connecting rod cap an...

Page 252: ...er to page B3 48 2 Installthe connecting rod caps as follows 1 Remove the Plastigage from the journals and bear ings 2 Apply a liberal amount of clean engine oil to the connecting rod bearings 3 Insta...

Page 253: ...k camshaft end play as follows 1 Measure camshaft end play End play 0 065 0 165 mm 0 025 0 064 in CYLINDER HEAD 1 Assemble in the order shown in the figure referring to Assembly Note 2 Install the roc...

Page 254: ...ve Assembly Note page B3 57 3 Valve seal 7 Gasket Assembly Note page 63 57 8 Cylinder head 4 Valve spring 9 Bolt Assembly Note page 63 57 Assembly Note page B3 11 Assembly Note Tappets 1 Coat the fric...

Page 255: ...alent and Valve Spring Compressor Bar T74P 6565 B or equivalent 2 lnstall the spring and spring seat Note lnstall the spring with the close coils toward the cylinder head 3 Compress the spring using V...

Page 256: ...fer to page B3 16 TIMING CHAIN 1 Assemble in the order shown referring to Assembly Note 2 Install the timing chain pulley key 1 Guide 4 Camshaft pulley Assembly Note below Assembly Note page B3 59 2 T...

Page 257: ...ft pulley referringto Assembly Note Refer to below 3 lnstall the crankshaft position sensor referringto Assembly Note Refer to page 63 60 4 lnstall the water pump referringto Assembly Note Refer to pa...

Page 258: ...p and water pump bolts 3 Tighten the water pump bolts Tightening torque 8 5 12 N m 0 83 1 24kgf m 6 9 ft lbf 4 lnstall the water pump pulley 4BUOB3 148 Baffle 1 lnstall the baffle 2 Tighten the nuts T...

Page 259: ...e oil filter and oil filter adapter referring to Assembly Note Refer to page B3 62 5 lnstall the fan assembly referring to Assembly Note Refer to below 6 lnstall the fuel supply manifold referring to...

Page 260: ...f m 26 30 ft lbf Fan assembly 1 lnstall the fan and clutch assembly 2 Hold the water pump pulley with the SST Tighten the clutch assembly with the SST Tightening torque 40 1 35 N m 4 1 1 3 8 kgf m 30...

Page 261: ...manifold gasket 2 Install the upper intake manifold 3 Tighten the upper intake manifold nuts Tightening torque 20 25 N m 2 1 2 4 kgf m 15 18 ftdbf Ignitioncoil pack 1 Install the ignition coil pack 2...

Page 262: ...pressure sensor 3 Engine coolant temperature sensor 4 Injectors 5 Intake air temperature sensor 6 Throttle position sensor 7 Water temperature indicator sender 8 Heated oxygen sensor 17 lnstall the p...

Page 263: ...arter mounting opening Tiahtenina toraue 45 61 fi m i 4 5 6 2 kgf m 3 3 45 ft lbf 6BUOB3 007 Engine mount nuts Tightening torque 88 1 15 N m 9 0 1 1 7 kgf m 65 45 ftelbf Accelerator cable shield Insta...

Page 264: ...hten the clamps Steps After Installation 1 Fill the engine with the specified amount and type of engine oil Refer to Section 03 2 Fill the radiator with the specified amount and type of engine coolant...

Page 265: ...IL PRESSURE Dl 4 PREPARATION Dl 4 INSPECTION Dl 4 ENGINE OIL Dl 4 INSPEiCTlON Dl 4 REPLACEMENT Dl 5 OIL FILTER Dl 5 REPLACEMENT Dl 5 OIL PAN1 Dl 6 REMOVAL I INSTALLATION Dl 6 INSPECTION Dl 7 OILPUMP D...

Page 266: ...pection page D l 4 Removal Installation page Dl 6 2 Engine oil Inspection page Dl 7 Inspection page D l 4 5 Oil pump Replacement page Dl 5 Removal Installation page Dl 8 3 Oil filter 6 Oil pump strain...

Page 267: ...0 Above 18 C O F SAE 1OW 30 Engine oil replacement with oil filter liters US qt Imp qt 4 7 I5 0 4 2 Oil capacity Engine oil replacement without oil filter 3 8 4 0 3 4 WD1025 D 6BUOD1 001 Oil pressure...

Page 268: ...ified checkfor the causeand repair as necessary Refer to TroubleshootingGuide MDIO61 A 6 Apply sealanttotheoilpressuresensorthreadsasshown 7 Remove the SST and install the oil pressure sensor Tighteni...

Page 269: ...or leaks 8 Check the oil level and add oil if necessary OIL FILTER REPLACEMENT 1 Remove the oil filter 2 Remove insert if necessary The insert is not normally removed for replacing filter 3 Use a clea...

Page 270: ...e the oil pan referring to Removal Note 5 Removethe oil pan gasket 6 Install in the reverse order of removal referring to Installation Note Removal Note Oil pan 1 Remove the bolts Caution Do not force...

Page 271: ...e panto the engineso the transmission mountingface of the oil pan is aligned with and square to the engine block 4 Install the engine oil pan Tightening torque 14 16 N m 143 1 62 kgfzm 1 24 141 in lbf...

Page 272: ...o Section B1 3 Removethe camshaft position sensor 4 Remove the oil pump referring to Removal Note 5 Install in the reverse order of removal referring to Installation Note Removal Note Oil pump 1 Remov...

Page 273: ...Note Camshaft position sensor Tightening torque d OIL PUMP STRAINER AND TUBE REMOVAL IINSTALLATION 1 Remove the engine Refer to Section 31 2 Remove the oil pan 3 Remove strainer and tube referringto R...

Page 274: ...PRESSURE D2 4 PREPAFlATlON 02 4 INSPEC TION 02 4 ENGINE OIL 02 5 INSPECTION D2 5 REPLACEMENT D2 5 OIL FILTER D2 6 REPLACEMENT D2 6 OIL PAN D2 7 REMOVAL INSTALLATION D2 7 INSPEC TION D2 7 OIL PUMP D2...

Page 275: ...Inspection page D2 4 Removal Installation page D2 7 2 Engine oil Inspection page D2 7 Inspection page D2 5 5 Oil pump Replacement page D2 5 Removal Installation page D2 9 3 Oil filter Disassembly Ass...

Page 276: ...4BUOD2 004 TROUBLESHOOTING GUIDE I Problem Possible Cause 1 Remedy I Page I Engine hard starting Improper engine oil 1 Insufficientenaine oil Excessive oil consumption Oil pressure drop gauge meter do...

Page 277: ...ssure sensor installation 1 hole Gauge oil pressure 3 Warm up the engine to normal operating temperature 4 Run the engine at 2 500 rpm and note the gauge read ings Oil pressure 2 7 6 4 1 3 kPa 2 8 4 2...

Page 278: ...1 2 5 0 A O ehe oil levelshouldbefilledtothetop ofthedashed 1 part of the dipstick DRAIN REPLACEMENT Warning Be careful when draining the oil is hot 1 Warm upthe engineto normaloperatingtemperaturean...

Page 279: ...small amount of clean engine oil to the O ring of the new filter 5 Installthe oil filter and tighten it by hand until the O ring contacts the cylinder block 6 Tighten the oil filter 112 turn after the...

Page 280: ...o lnstallation Note I I MD1036 C 5BUOD2 008 1 Oil pan 2 Gasket Removal Note page D2 7 Inspection page D2 7 InstallationNote page D2 8 Removal Note Oil pan Note The oil pan fits tightly between the tra...

Page 281: ...he cylinder block as shown in the figure 3 Apply a 4 6 mm 0 16 4 23 in bead of sealant to the cylinder block betweenthe guide pin hole and the timing chain cavity as shown in the figure 4 Position a n...

Page 282: ...ring to InstallationNote N rn kgfm ft lbf MD1039 A 5BUOD2 010 1 Oil pump 2 Oil pump intermediate shaft Disassembly1 Assembly Refer to Section D3 Inspection page D2 10 InstallationNote Oil pump bolt 1...

Page 283: ...earance 0 30 mm 0 012 in Relief spring tension 28 2 mm 1 11 in 21 22 kgf 9 1 10 1 Ibf c MDlO31 A Note Internal components are not serviced If any com ponent is out of specification the pump assembly m...

Page 284: ...SPECTION D3 4 ENGINE OIL D3 5 INSPECTION D3 5 REPL ACEMENT 03 5 OIL FILTER D3 6 REPLACEMENT D3 6 OIL FILTER ADAPTER D3 6 REMOVAL1 INSTALLATION D3 6 OILPAW D3 7 PREPARATION D3 7 REMOVAL INSTALLATION D3...

Page 285: ...e Inspection 2 Engine oil Inspection Replacement 3 Oil filter Replacement 4 Oil filter adapter Removal Installation I 4BUOD3 002 5 Oil pan page D3 4 Removal Installation page D3 7 Inspection page D3 8...

Page 286: ...ent engine oil Add oil f 5 D3 5 Excessiveoil 1 0 1 1 working up or down Refer to Sectlon B3 consumption I Oil leakage Repa r Oil pressuredrop 1 lnsuffic ent oil Add oil 0 1 1 leakage Repair 1 Worn and...

Page 287: ...ne at 2000 rpm and note the gauge readings Oil pressure 2 7 6 4 13 kPa 2 8 4 2 kgf cm2 40 60 psi 2 000 rpm 5 If the pressureis notas specified checkfor the causeand repair as necessary Refer to Troubl...

Page 288: ...e careful when draining the oil is hot 1 Warm upthe engineto normaloperatingtemperature and stop it 2 Removethe oil filter cap and the oil pan drain plug 3 Drainthe oil into a suitable container 4 Ins...

Page 289: ...ilter 5 Install the oil filter and tighten it by hand until the O ring contacts the oil filter adapter 6 Tighten the oil filter 112 turn 7 Start the engine and check for leaks 8 Check the oil level an...

Page 290: ...al referringto lnstallation Note 49 UNOl 136 0 a d Rear main seal m oil seal pilot and 1 seal replacer 1 t MD1012 C 1 Spacer InstallationNote page D3 9 2 Oil pan InstallationNote page D3 10 3 Oil pump...

Page 291: ...and damage Repair or replace if necessary 4BUOD3 013 Installation Note Note Remove all foreign material from all contact sur faces 4BUOD3 014 Main bearing cap 1 Apply sealant to the main bearing cap 2...

Page 292: ...0 3 0 1 8 Spacer Note Thespacersareusedtodeleteanygapbetweenthe oil pan and transmission STRAIGHTEDGE PADS 1 Use the following steps to determine spacer thickness 1 Attach the oil pan to the cylinder...

Page 293: ...4 Installthe oil pan 5 lnstall and finger tighten the oil pan nuts 6 Align the rear of the oil pan with the rear of the cylinder block Note Appropriate spacers should be installedif the rear of the oi...

Page 294: ...ten the oil pan bolts and nuts Tightening torque 7 10 N m 0 69 4 96 kgfem 5 7 ft lbf OIL PUMP REMOVAL I INSTALLATION Refer to page D3 8 DISASSEMBLYIASSEMBLY 1 Disassemblein the order shown in the figu...

Page 295: ...he outer race and the rotor and shaft assembly Caution Make sure the dimple identification mark on th outer race is facing outward on the same side as the identification mark on the rotor The rotor an...

Page 296: ...El 5 AIR BLEEDING E l 5 RADIATOR CAP El 6 INSPECTION El 6 RADIATOR El 7 REMOVAL INSTALLATION El 7 INSPECTION El 8 THERMOSTAT El 9 REMOVAL INSTALLATION El 9 INSPECTION El 10 WATER PUMP El 12 REMOVAL IN...

Page 297: ...olant Inspection Replacement Air Bleeding 2 Radiator Cap Inspection 3 Radiator Removal Installation Inspection 4 Thermostat page E1 4 Removal Installation page E l 9 page E1 5 Inspection page E l 10 p...

Page 298: ...occurwhile the powertraincontrol module relearnsitsadaptivestrategy The vehicle may need to be driven 16 km 10 miles or more to relearnthe strategy 4BUOE1 004 Cooling fan TROUBLESHOOTING GUIDE I Probl...

Page 299: ...TECTION SPECIFIC GRAVITY 10 0 10 20 30 40 50 60 70 80 90 141 321 50 68 86 104 122 140 158 176 194 COOLANT TEMPERATURE C F Coolant Leakage 1 Connect a radiatortester commercially available to the radia...

Page 300: ...6 Runthe enginewith the filler cap removed untilthe upper radiator hose is hot 7 With the engine idling add coolant to the radiator until it reachesthe bottom of the filler neck 8 Installthe radiatorc...

Page 301: ...CAP INSPECTION Radiator Cap Valve 1 Remove all foreign matter such as water residue from betweenthe radiator cap valve and the valve seat 2 Attach the radiator cap to a radiator cap tester commer cia...

Page 302: ...nect the negative battery cable 2 Drain the engine coolant 3 Remove in the order shown in the figure 4 Install in the reverse order of removal referringto Installation Note I I ME1039 8 5BUOE1 005 I O...

Page 303: ...ooler line fittings from the old radiator and install them on the new radiator 5BUOE1 006 Radiator hose upper Positionthe hoseon the radiator necksothatthe stripe on the hose is at the 12 o clock posi...

Page 304: ...tery cable 2 Drain the engine coolant 3 Disconnect the heater return hose from the thermostat housing 4 Remove in the order shown in the figure 5 Install in the reverse order of rernoval referringto l...

Page 305: ...t Electrical Note Thistest shouldbeperformedat temperatures less than 37 S C 100 F ambient air 1 Hook up the New GenerationStar NGS tester Referto Section FT Note For an accuratetest readingthe engine...

Page 306: ...is criticalthat the correct thermostat installation alignment is made to provide coolant flow to the heater Install the thermostat into the thermostat cover and rotate the thermostat into the water o...

Page 307: ...r pulley in a counterclockwisedirection and remove the drive belt 6 Remove the water pump pulley 7 Disconnect the heater hose from the water pump 8 Remove the timing belt outer cover 9 Disconnect the...

Page 308: ...REMOVAL IINSTALLATION 1 Disconnect the negative battery cable 2 Drain the engine coolant 3 Remove in the order shown in the figure 4 Install in the reverse order of removal I ME1011 B 5BUOE1 00 1 Fan...

Page 309: ...ery cable 2 Drain the engine coolant 3 Remove in the order shown in the figure referringto Removal Note 4 Install in the reverse order of removal referringto lnstallation Note 1 Block heater cable Rem...

Page 310: ...d e g 6 o clock 12 o clock when removing heater 2 Clean insidediameterof core plug holemachinedsurface and hole entrance Removeany burrsat hole entranceto avoid damage to O ring 3 Cover rubber O ring...

Page 311: ...BLEEDING E2 6 RADIATOR CAP E2 7 INSPECTION E2 7 RADIATOR E2 8 REMOVAL INSTALLATION E2 8 INSPECTION E2 9 THERMOSTAT E2 10 REMOVAL INSTALLATION E2 10 INSPECTION E2 11 WATER PUMP E2 13 REMOVALIINSTALLATI...

Page 312: ...age E2 6 2 Radiator cap lnspection page E2 7 3 Radiator Removal 1 lnstallation page E2 8 lnspection page E2 9 I 5BUOE2 001 4 Thermostat Removal lnstallation page E2 10 lnspection page E2 11 5 Water pu...

Page 313: ...yoccurwhilethe powertraincontrolmodulerelearnsitsadaptivestrategy Thevehicle may need to be driven 16 km 10 miles or more to relearn the strategy 4BUOE2 004 TROUBLESHOOTING GLJIDE I Problem Possible C...

Page 314: ...Verify that the coolantinthe reservoir isat the COLD FILL mark Add coolant as necessary 5BUOE2 002 Coolant Quality 1 Verify that there is no buildup of rust or scale around the radiator cap or filler...

Page 315: ...tectionisnotproper addwater or coolant as necessary Antifreeze solution mixture percentage Volume percentage G I Coolant protection I Above 24 C 11OF I 60 1 40 I I Above 52 C 62 F 40 60 ME1007 D COOLA...

Page 316: ...cessary AIR BLEEDING When refilling the cooling system after draining the coolant perform the following 1 Slowly pour the coolant into the radiator up to the filler neck 2 Fill the coolant reservoir t...

Page 317: ...ator cap tester commer cially available and apply pressure gradually to 83 kPa 0 9 kgfIcm2 12 psi 3 Verify that the pressure is held for at least 10 seconds Negative Pressure Valve 1 Pull the negative...

Page 318: ...clockwise direction 4 Remove the drive belt 5 Disengagethe constant tension hose clamps from the bypass fitting connection 6 Remove in the order shown in the figure 7 Install in the reverse order of r...

Page 319: ...05 Radiator hose upper Positionthe hoseonthe radiatornecksothat the stripeon the hose is at the 12 o clock position 4BUOE2 017 Radiator hose lower 1 Position the hose on the radiator with the stripe o...

Page 320: ...the negative battery cable 2 Drain the engine coolant 3 Remove in the order shown in the figure 4 Install in the reverse order of removal referring to lnstallation Note GASKET REPLACE N m kgf m ft lb...

Page 321: ...lectrical Note Thistest shouldbeperformedattemperaturesless than 37 8 C 100 F ambient air 1 Hook upthe New Generation Star N GS tester Referto Section FT Note Foran accuratetest readingthe engine cool...

Page 322: ...s criticalthat the correct thermostat installation alignmentismade to providecoolantto the heater Installthe thermostatintothe thermostatcover and rotate the thermostat into the water outlet connector...

Page 323: ...nthe water pump pulley bolts 6 Lift the drive belt tensioner pulley in a clockwise direction and removethe drive belt 7 Remove the water pump pulley 8 Removethe generator adjusting arm and bracefrom t...

Page 324: ...tallthe water pump bolts Bolt length A Length M8 x 1 25 0 Length M6 x 1 OO Tightening torque A 25 N m 2 7 kgf m 19 ft lbf 6 10 N m 1 0 kgf m 7 ft lbf Note Apply clean engine oil to all bolt and stud t...

Page 325: ...r of removal referring to InstallationNote 1 Cooling fan 2 Clutch Removal Note below Installation Note page E2 16 Removal Note Cooling fan 1 Remove the two fan shroud attaching screws and lift the fan...

Page 326: ...ightening torque 6 8 N m 61 2 41 6 kgf cm 53 70 in lbf 2 Install the clutch on the water pump Tightening torque 41 1 35 N m 14 1 1 3 8 kgf m 30 1 00 ft lbf Caution The nut which attaches the clutch to...

Page 327: ...el removingtool or equivalent to remove wiringfrom batterytray innerfender engine mountbrackets and cylinder block 6 0 2 1 0 3 Block heater 1 Note positionthat element is pointed e g 6 o clock 12 o cl...

Page 328: ...LEEDING E3 6 RADIATOR CAP E3 7 INSPECTION E3 7 RADIATOR E3 8 RENIOVALIINSTALLATION E3 8 INSPECTION E3 10 THERMOSTAT E3 11 REMOVAL INSTALLATION E3 11 INSPECTION E3 12 WATER PUMP E3 14 REMOVALI INSTALLA...

Page 329: ...spection page E3 4 Replacement page E3 5 Air bleeding page E3 6 2 Radiator cap Inspection page E3 7 3 Radiator Removal1 Installation page E3 8 Inspection page E3 10 I 5BUOE3 001 4 Thermostat Removal I...

Page 330: ...en the battery has been disconnected and reconnected some abnormal drive symptoms may occurwhilethe powertraincontrolmodulerelearnsitsadaptive strategy The vehicle may need to be driven 16 km 10 miles...

Page 331: ...neck 2 Verifythat the coolantinthe reservoir is at the COLD FILL mark Add coolant as necessary Coolant Quality 1 Verify that there is no buildup of rust or scale around the radiator cap or filler nec...

Page 332: ...ydrometer 2 Determinethe coolantprotectionbyreferringtothegraph as shown 3 If the coolant protection is not proper add water or coolant as necessary Antifreeze solution mixture percentage I Above 24 C...

Page 333: ...hose is hot 7 With the engine idling add coolant to the radiator until it reaches the bottom of the filler neck 8 Installthe radiator cap 9 Verify that the coolantinthe reservoir is at the COLD FlLL...

Page 334: ...reservoir is at the COLD FILL mark Add coolant as necessary RADIATOR CAP INSPECTION Radiator Cap Valve 1 Remove all foreign matter such as vvater residue from betweenthe radiator cap valve and the val...

Page 335: ...originalpositiononthe hose andsqueezethe clamplightlywith large pliers to ensure a good fit 1 Disconnectthe negative battery cable 2 Drain the engine coolant 3 Remove in the order shown in the figure...

Page 336: ...UOE3 004 I Overflow hose 5 Transmission cooler lines 2 Fan shroud InstallationNote page E3 10 3 Radiator hose upper 6 Radiator InstallationNote page E3 10 Inspection page E3 10 4 Radiator hose lower I...

Page 337: ...install them on the new radiator 5BUOE3 003 Radiator hose upper Positionthe hoseonthe radiator necksothat the stripe on the hose is at the 12 o clock position 4BUOE3 018 Radiator hose lower Position t...

Page 338: ...Drain the engine coolant 3 Remove in the order shown in the figure 4 Install in the reverse order of removal referringto lnstallation Note GASKET 4 I f P i nc laci q y VIEW A I I ME1024 C 6BUOE3 007...

Page 339: ...be running 2 Make sure AIC switch is in OFF position 3 Place the vehicle in Park P or Neutral N 4 Startthe vehicle and allowthe engineto runfor 2 minutes 5 Record the Engine Coolant Temperature ECT se...

Page 340: ...thermostat housing making sure that the air release valve is in the up position Installthe thermostat intothe thermostat cover and rotate the thermostat into the water outlet connector in a clock wis...

Page 341: ...n the reverse order of removal referringto Installation Note 6BUOE3 011 Installation Note Gasket 1 Clean the surface of the gasket on the front cover and on the water pump Note Use care when scraping...

Page 342: ...ant 3 Remove in the order shown in the figure referringto Removal Note 4 Install in the reverse order of removal referringto Installation Note For removal and installation of the cooling fan clutch Fo...

Page 343: ...water pump using the SST Caution The nut which attaches the clutch to the water pump shaft has a left hand thread and must be rotated clockwise for removal InstallationNote Cooling fan 1 Install the...

Page 344: ...le 2 Drain the engine coolant 3 Remove in the order shown in the figure referringto Removal Note 4 Install in the reverse order of removal referringto lnstallation Note ME3001 A 6BUOE3 015 1 Block hea...

Page 345: ...ted e g 6 o clock 12 o clock when removing heater 2 Cleaninsidediameterof coreplugholemachinedsurface and holeentrance Removeany burrsat hole entrance to avoid damage to O ring 3 Cover rubber O ring w...

Page 346: ...PCV VALVE FOR 2 3L 14 OL FT 157 PCV VALVE FOR 3 OL FT 157 EXHAUST GAS RECIRCULATION EGR FUNCTIONCONTROL SYSTEM FOR 2 3L 3 OL 4 OL FT 158 DESCRIPTION FT 158 EGR VACUUM REGULATOR SOLENOID FT 158 EGR VAL...

Page 347: ...ion page F3 6 5 Intake manifold Removal1 Installation page F3 4 Inspection page F3 6 6 Accelerator pedal not shown Removal Inspection Installation page F3 7 7 Accelerator cable not shown Inspection Ad...

Page 348: ...wn Removal Inspection1 Installation page F2 7 5 Accelerator cable not shown Removal Inspection Installation page F2 7 6 Intake manifold Removal Installation page F2 2 7 Pressure regulator Inspection p...

Page 349: ...F1 4 5 Intake manifold Removal Installation page F1 3 Inspection page F1 4 6 Accelerator pedal not shown Removal Inspection Installation page F1 5 7 Accelerator cable not shown Inspection Adjustment p...

Page 350: ...ation pages F2 11 F3 15 2 Three way catalytic converter Removal Installation pages F2 11 F3 15 Inspection page FT 156 3 Front pipe assembly Removal 1Inspection Installation pages F2 11 F3 15 4 Exhaust...

Page 351: ...NT OF VEHICL VlEW C VIEW A 3 FRONT OF VEHICLE FRONT OF VEHICLE VIEW B 1 Silencer 3 Exhaust manifold Removal Inspection Removal 1Inspection Installation page F1 9 Installation page F1 9 2 Three way cat...

Page 352: ...I REGULAR CAB 1 Fuel tank 3 Fuel pump Removal Inspection Inspection page FT 151 Installation page F3 9 Removal Installation page F3 12 2 Fuel filter low pressureside 2 Fuel vapor valve Replacement pag...

Page 353: ...FT INDEX FOR 4 OL 3 OL 12 3L...

Page 354: ...pection page FT 163 2 3L 3 OL page FT 192 20 Heatedoxygen sensors not shown Inspection Inspection page FT 188 2 3L 3 OL page FT 192 Removal 1Installation page FT 188 4 OL page FT 192 21 Transmission r...

Page 355: ...I I Voltage Resistance 11 18 at 20 C 68 F Idle air solenoid I Crankshaft position sensor 1 Solenoid resistance I Type Variable reluctance 1 6 13 at 20 C 68 F I Mass air flow sensor I I Evaporative em...

Page 356: ...MA SENDER RL 8 1002 VEHICLE SPEED SENSOR X01 ENGINECOMPARTMENT FUSURELAY BOX OPHJ wSS ECE X 02 I I P FUSEPANEL MA X 114 COMMONCON ECS ECE X 124 COMMONCON ECSMDPHJ X 129 COMMONCON ECS ECE XI36 COMMONC...

Page 357: ...1 R I DPW BRRB T B LGIO T W BWY ECS ECS ECS ECS ECS ECS BILG GYM ESC ECS B 7a TW TW SEE COMMON CONNECTOR UST SECTION X 4 oL IGNITION SYSTEM ENGINE CONTROLSYSTEM I In...

Page 358: ...B 8 4 0L ENGINE CONTROL SYSTEM 4WABS SYSTEM SECTION0 1 METER SECTIONGla 8 DATA LINKCONNECTOR DLC 0 METER SECTIONGla 6 T HEATER AND AK SECTIONG 1 1 T T...

Page 359: ...ECQ 0 8 ECE I I E M ECS BWO ECS O N ECS PUlO ECS P B ECS PUN ECS WN ECS 0 8 fECS1 CONNECTOR OLC BIW MA GYN P N R T I M T W W Y W D W I D G D BWP TN L B W W I B W V m LBIBPh8Tm DL GY I w e vm x U 8 207...

Page 360: ...M ENGINE SECTION6 8 ENGINE GYIR ECE SECTIONB h SECTION 8a BMl WW GYRB DPW ECS ECS YLB ECS RIB ECS W D ECS WLG ECS B 9 X124 COMMONCON ECS DPW XI29 COMMONCON ECE ECS X 128 COMMONCON ECQ ECS XI36 COMMONC...

Page 361: ...D SENSOR X 01 ENGINECOMPARTMENT FUSEIRELAY BOX DPKI SENDER RL vSS W E X 02 llP FUSE PANEL lMAl X 114 COMMONCON ECS ECE X 124 COMMONCON ECS DPKI X 129 COMMONCON ECS ECE X 136 COMMONCON MA DPKI X 201 CO...

Page 362: ...B 4a 3 OL IGNITIONSYSTEM ENGINE CONTROL SYSTEM...

Page 363: ...N0 1 SECTION C la METER HEATER AND N C DATA UNK CONNECTOR DLC GY R B 5 X 128 COMMON CONNECTOR ECE ECS X 134 COMMON CONNECTOR MA DPHJ X 136 COMMON CONNECTOR MA DPHJ SEE COMMON CONNECTORUST SECTIONX 3 0...

Page 364: ...OUTLINE FT...

Page 365: ...HJ X 02 I F FUSE PANEL MA X 114 COMMONCON ECE ECS B 6 X 124 COMMONCOh ECSI DPMJ X 128 COMMON CON lECE ECS 3 0L ENGINE CONTROL SYSTEM X 129 COMMONCON ECE ECS X 136 COMMONCON MA DPHJ X 213 IGNITION SWIT...

Page 366: ...0 PILG DPHJ DpW DPHJ _ _____ __ __ LBB PU PILB TI0 PlLG P N DGIO t ECS ECS ECS ECS ECS ECS ECS e 9 0 8 69 6 3 8 POWERTR INCONIROLMOWi EiPCM 8 a rrt INTAKE AIR TEMPERATURE TEMPERATURE 6 1 12 ECT SENSOR...

Page 367: ...J 0 T SYSTEM T SECTION8 2 8 207 X 136 R ECE 8 TAN MA t TAN DPHJ T X 124 GY R WE R ECE R ECE R ECE GYIR ECE TAN ECS WILG ECS DATA LINK CONNECTOR DLC DGMECE BRIO ECE O N ECE PUIO ECE P B ECE PUN ECE W N...

Page 368: ...S GY R ECS X 114 WIB ECS RlLG ECS WIB ECS WLG ECS HEATED OXYGEN I A I J J 1 DG Y I SENSOR ECS AIT 7 t M K I WIB WLG ECS ECS 8 3 a B 111 POWERTWIN CONTROLMODULEIPCM POWERTRAINCONTROLMODULE IPCM 2 3L EN...

Page 369: ...ECS ECS T N T N I T N MA B 1a 2 3L IGNITIONSYSTEM 8 ENGINE CONTROL SYSTEM XI24 ENGINE I R DPW 1 DPHJ R ECS R ECS R ECS R ECS R ECS 8 105 MASS AIR FLOW MAF t t SENSOR SOLENOID 0 W BILG WllB 0Rm T BWLB...

Page 370: ...ENGINECOMPARTMENT FUSURELAYBOX DPHJ SWITCH MA MA IFS SWITCH MA SENDER RL VSS W E X 02 I I PFUSE PANEL MA XI14 COMMONCON ECS ECE X 124 COMMONCON ECS DPHJ X 130 COMMON CON ECSI ECE X 136 COMMON CON MA...

Page 371: ...ne load On PJT model jumper is connectedto connector Applies and releases coast clutch PCM outputs driver signals to solenoids Monitorstrigger wheel to indicatecrankshaft positionand speed information...

Page 372: ...ragm operated relief valve One side of diaphragm senses fuel pressure and other side is connected to intake manifold vacuum Balancing one side of diaphragm with manifold vacuum maintains a constant fu...

Page 373: ...erature decreases Sensor is connected to voltage divider so that varying resistance of sensor causes a variation in total current flow Dropped voltage across a fixed resistor in a series with sensor d...

Page 374: ...ureand sends signalto PCM PCM controls the following 1 Adjusts idle rpm 2 Adjusts transmissionline pressureduring increasedengine load PCM has a 104 pinelectricalconnector PCM power relay Power steeri...

Page 375: ...oid Transmission control Outputs keypower whenever TCS is cycled switch TCS to PCM DisengagesA C clutch during the following conditions Engine cranking Engine overheated Wide open throttle Uses a mome...

Page 376: ...he customer you will usually find out what the symptoms are and under what conditionsthey occur 4BUOF3 010 Work flow CHECK IN REFERTOTROUBLESH0C TINGPAGETHAT DIAGNOSTICINDEX CORRESPONDSTO ACTUAL SYMPT...

Page 377: ...camshaft position sensor s gnai at PCM INSPECTION page FT 165 If OK check as follows Crankshaft pos tion sensor page FT 162 High tension leads Section G Spark plugs If not OK check wiring harness s G...

Page 378: ...deceleration gine missesduring accelerationor cruising 1 Vehicle bucksljerks during acceleration cruising or deceleration 1 durina acceleration Momentary pause at beginning of acceleration or i Hesita...

Page 379: ...continuously 28 N C does not cut off under wlde open throttle condrtlons FT 131 DTCs or to actrvate KOEO or KOER self 33 Retrleve DTC not llsted FT 131 29 30 31 A C compressor magnetlc clutch does no...

Page 380: ...30A PCM PWR fuse PCM Y PCM Y ELEC SHIFT 20A ELEC SHIFT fuse Electr c shift control unit DGILG I PWR LOCKSNVINDOWSISEATS PWR LOCWWINDOWISEAT fuse Rlght power lumbar swltch BIW 2 0 4 Left power bolster...

Page 381: ...START No i Go to step 3 Yes Check for seized hydrolockedengine flywheel I For 2 3L Section B1 For 3 OL Section B2 For 4 OL Section B3 2 Service as required Section G Go to next step Check the chargin...

Page 382: ...ure regulator diaphragm D P page FT 154 High Check pressure regulator for high pressure cause epage FT 154 Check for clogged fuel return li ie Go to next step Are any diagnostictrouble codes displayed...

Page 383: ...contamination No Disconnectvacuum hose from EGR valve and plug it Does condition improve Check evaporative emission system as follows Disconnect evaporative hose and place a stiff piece of paper over...

Page 384: ...engine run smoothly at part throttle Yes Diagnostic trouble code Check for cause Referto Diagnostic Trouble Code chart a a e FT 77 Are any diagnostic trouble codes displayed during Key On EngineOff o...

Page 385: ...ep Check pressureregulatordiaphragm page FT 154 If condition is OK check injector page FT 155 If condition is not OK replace pressure regulator i Visually look for fuel leakage at injector O ring pres...

Page 386: ...on Inertiafuel shutoff IFS switch is set I STEP 1 INSPECTION I ACTION 1 Are any diagnostic trouble codes displayed during Key On Engine Off or Continuous Memory inspection page FT 71 Yes Diagnostic t...

Page 387: ...Pin 13 module programming signal at data link connector and battery negative post Is voltage greater than 9 0 volts Is a strong blue spark visible at each disconnected No Check camshaft pos t on senso...

Page 388: ...n x t i i No V e r i f y i t results If OK return to diagnostic index to service any additional symptoms ENGINE RUNS ROUGHIROLLINGIDLE ATIDLE DESCRIPTION Engine speed fluctuates between specified idle...

Page 389: ...ssureHold Inspection page FT 150 Does fuel l ne pressure hold Crank engine for 5 seconds Does pressure drop more than 34 kPa 0 35 kgflcm2 5 psi by the end of 5 second crank cycle No Is strong blue spa...

Page 390: ...k engine coolant temperature sensor PID Start engine and warm to operating temperature Does ECT sensor PIDvoltage remain greater than For 2 3L Section E l 0 3 volts temperature less than 116 C 240 F F...

Page 391: ...ce pressure regulator ACTION Go to step 3 Go to next step p p p p Diagnostic trouble code displayed Check for cause refer to Dlagnostlc Trouble Code chart page FT 77 STEP INSPECTION Yes No I No Check...

Page 392: ...ace a stiff piece of paper over the hose end Does vacuum hold the paper 4 Perform Fuel Line Pressure Inspection page FT 150 Is fuel line pressure correct Remove PCV valve and shake it Does PCV valve r...

Page 393: ...go to next step If not OK clean or replace spark plugs Yes Check exhaust system page FT 156 No No Go to next step Check as follows High tension leads c Section G Crankshaft positionsensor g Section G...

Page 394: ...piece of Does vacuum hold paper If yes check evaporative ernission system page FT 160 If no check for vacuum leak in PCV system oil cap PCV valve rocker cover for bolt torquelgasket leak Perform Fuel...

Page 395: ...here a restriction in exhaust system7 Yes page FT 156 L No Check exhaust system Go to next step page FT 156 i Is air leakage felt or heard at intake air system components while racing engine to higher...

Page 396: ...180 INSPECTION ACTION Are any diagnostic trouble codes Key On Engine Off Key On Engine Runningor Check for cause refer to Diagnostic Trouble Code No Continuous Memory inspection page FT 71 Perform Fue...

Page 397: ...4 Visually look for fuel leakage at injector O ring L r e s s u r e regulator and fuel line Service as 1 necessary Check pressure regulator diaphragm condition Perform Fuel Pressure Hold Inspection pa...

Page 398: ...vent on vacuum hose to EGR valve for obstruction or leak If OK replace EGR vacuum regulator solenoid If not OK repair or replace vacuum line No 1 Go to next step Yes 1Go to next step Does EGR valve s...

Page 399: ...for 5 seconds Does pressure drop more than 34 kPa 0 35 kgf cm2 5 psi by the end of 5 second crank cycle No diagnostictrouble codes displayed Is strong blue spark visible at each disconnected high ten...

Page 400: ...psi Diagnostic trouble code displayed Check for cause refer to DiagriosticTrouble Code chart page FT 77 No diagnostictrouble codes displayed Go to next step Repair or replace poor connec1 ionin circui...

Page 401: ...s only aSection K Is automatic transmission OK Yes Go to next step Check for cause Section K Is engine compression correct ux For 2 3L Section B1 For 3 OL Section 82 For 4 OL Section 83 Remove PCV val...

Page 402: ...agm page FT 154 Check fuel pump circuit g page FT 151 High Check pressure regulator for high pressurecause page FT 154 Check for cloaaedfuel return line Yes Go to next step I Go lo next step No Discon...

Page 403: ...If no check for vacuum leak in PCV system oil cap PCV valve rocker cover for bolt torquelgasket leak Is engine compressioncorrect Is air leakage felt or heard at intake air system I Yes Repair or rep...

Page 404: ...played during Key On Engine Off Key On Engine Running or Continuous Memory in spec ti or page FT 71 Yes 1 Diagnostic trouble code displayed Check for cause refer to DiagnosticTrouble Code chart No dia...

Page 405: ...box greater than 2 0 volts Does the TClL remain on I Verify test results If OK return to diagnostic index to service any additional symptoms Key OFF j Install breakout box Leave PCM disconnected Key...

Page 406: ...at normal temperature i Blue IGo to next step Yes No Yes No White IGo to step 4 I 1 Black Go to step 5 I Remove PCV valve and shake it Does PCV valve rattle 1 Yes Goto next step No 1 Replace PCV valve...

Page 407: ...essure drop more than 34 kPa C0 35 kgflcm2 5 psi by the end of 5 second crank cycle high tensionleadwhile cranking engine If OK go to next step If not OK clean or replace spark plugs High tensionleads...

Page 408: ...V system oil cap PCV valve rocker cover for bolt torquelgasket leak Removea plug line to evaporative emission canister Remove gas cap and installa vacuum pumplgaugegas cap Apply air pressure Air press...

Page 409: ...L Section B1 For 3 OL Section 82 For 4 OL Section 83 Engineoil level Drive belts Tappets and push rods Go to next step Check drive belt Go to next step Check location of rattlefor loose parts Go to ne...

Page 410: ...and ACCS Removejumper wire Refer to 1997 B series BETMto check the heater and air conditioning systems Key OFF DisconnectN C cycling switch ACCS Install a jumper wire in the ACCS vehicle harness conne...

Page 411: ...t box leave PCM disconnected e ON 6 Key OFF Connect wide open throttle N C cutout I I Yes Replace PCM relay N C cycling switch disconnected Breakout box installed PCM disconnected Kev ON Refer to the...

Page 412: ...I 1 2 1 Refer to the 1997 B series BETlW to check the wide I Yes Go to next steo I No open throttle N C cutout relay Is the wide open throttle A C cutout relay OK F F p c e wide bpen throttle NC Go to...

Page 413: ...FT 71 4 Start engine Disconnectcrankcase ventilation hose from the throttle body Place a stiff piece of paper over the hose end Does vacuum hold the paper Yes Yes No Zero or low Check pressure regulat...

Page 414: ...fy repair suspect component wire component or vacuum line If fault occurred while spraying vviring related to possible fault area Inspect each wire for corrosion bent or loose Are any PID values out o...

Page 415: ...When a fault is detected a Diagnostic Trouble Code DTC will be output on the data link when requested by a scan tool 6BUOFT 041 RetrieveIClear Continuous DTC Self Test Continuous DTC access is also a...

Page 416: ...r or ohmmeter Do not use the adapter to pull DTCs MF1667 A I 1 4 Listenfor a double beep SST NGS is now initialized It will briefly display the system check screen DIAGNOSTIC LlNK MODULE 85 96 VlNl V2...

Page 417: ...riate model Press the trigger P I key to enter this selection 1 6 he vehicle selection screen showing the selected 96 4 0L MAN 84000 VIEW RECORDERAREAS DIGITALMEASUREMENTSYSTEM GENERIC OED FUNCTIONS I...

Page 418: ...n a piece of paper and proceed to the KOEO test Note The purpose of recording continuous DTCs at this time is to make sure they are not uninten tionally cleared during any KOEO or KOER service KOEO an...

Page 419: ...ear Codes function in GENERICOBD I IFUNC TIONS and clear DTCs 3 Perform Quick Test to ensure customer s concern has been resolved If DTC PI000 is present go to that DTC chart I I MF1693 A 5BUOF3 050 I...

Page 420: ...s showing the transformation of values to the line graph Output Test Mode Procedure 1 Hook up SST NGS to data link c onnector Refer to page FT 71 2 Performstep 1throughstep 9 from Retrieving DTC s Pro...

Page 421: ...nstructedto do SO 1 Start the engine 2 Drive vehicle in any mode for 4 minutes 3 Monitor ECT PID drive vehicle until ECT PID reaches 0 6 volts 180 F 82 C or greater 4 Idle for 80 seconds 5 Accelerate...

Page 422: ...H02S 11 Responserate of H02S 11 is below calibratedwindow FT 90 1 PO135 1 H02S HTR 11 H02S 11 heater circuit has a short to ground open or short to VPWR I FT 92 I H02S 12output voltage is less than ca...

Page 423: ...ensor A VSS Powertrain Control Module PCM has experienced a power interrupt in Keep Alive Power KAPWR I FT 126 I PCM circuit PCM detected a loss of TSS signal during operation PCM detected loss of VSS...

Page 424: ...Engine Coolant Temperature ECT PI117 ECT signal went below 0 3 volt or above 3 7 volts during KOEO or KOER self test 1 ECT signal was not received during KOEO and KOER self test but was output during...

Page 425: ...it malfunction p i Sect on G Loss of Spark Output SPOUT s gnal Sect on G PI390 1 OCT ADJ Shorting Bar I OCT ADJ shorting bar is not in or OCT ADJ circuit is open PI409 EGR Vacuum Regulator EVR Solenoi...

Page 426: ...P1747 EPC Solenoid EPC circuit shorted P1749 EPC solenoid failed low I P1751 1 Shift Solenoid 1 SS1 SSl functionalfailure mechanicalor hydraulicfailure Section K I rP1754 I coast clutch Solenoid CCS c...

Page 427: ...eakout box reconnect PCM Key ON engine off r a the vehicle harness closest to MAF sensor connector Key OFF Inspectfor damaged or pushed out pins corrosion loose wrres at MAF or PCM connector Repair or...

Page 428: ...nnect PCM Is the resistance between PWR GND B circuit at MAF sensor connector and battery negative terminal less than 10 0ohms No 1 Repair open in PWR GND circuit 1 GOto step 21 1 i Key OFF Leave MAF...

Page 429: ...sor Replace MAF sensor Remove jumper Go to step 19 No Remove jumper Go to next step Key OFF MAF sensor disconnected Install breakout box leave PCM disconnected Key ON engine off Is the voltage between...

Page 430: ...or connector Go to next step Key ON engine off Measurevoltage between VREF and SIG RTN circuit at TP sensor connector Is voltage between4 0 and 6 0 volts No Go to pinpoint test VREIZ Yes For ECT senso...

Page 431: ...T or IAT circuit to ground at breakoutbox j Go to step 15 Is each resistancegreater than 10 000ohms Key ON Yes Replacesensor Access ECT or IAT PID Go to step 15 Monitor PID while performingthe followi...

Page 432: ...ector Repair or replace if necessary Follow directionin Action TP SIG shorted to VREF or SIG RTNopen in TP sensor ReplaceTP sensor I Go to step 11 Is ohage bGtween VREF and SIG RTN circuit at TP Go to...

Page 433: ...est pin 91 and PWR GND test pin 24 or 103 at breakout box 1 Is each resistance greater than 10 000ohms 1 Yes I Go to next step No Repair open In TP SIG clrcult I Go to step 23 15 I Yes Replace PCM 1 G...

Page 434: ...um 4 60 volts 92 27 1 Yes Isolatefault and repair or replace as Installbreakout box reconnect PCM necessary Kev ON enaine off Go to step 23 easur6 votage betweenTP SIG test pin 89 and SIG RTNtest pin...

Page 435: ...connected Key OFF Yes ReplaceH02S and oillfilter Disconnect suspect H02S connector Complete PCM reset to clear DTCs and H02S Jumper H02S SIG to VPWR at H02S connector 1 monitordrive cycle Connect scan...

Page 436: ...KOUT BOX VIEW FROM PIN SIDE FRONT CYL ENGINE 6 CYL Signal VPWR Wire Color Test Pin SIG RTN H02S SIG 11 H02S HTR 11 GND H02S SIG 12 1 H02S HTR 12 GND H02S SIG 21 H02S HTR 21 GND I INJECTORS I CYLINDERS...

Page 437: ...Is resistance less than 4 0 ohms Check fuse If fuse is OK repair open circuit Go to step 11 Key OFF Disconnect suspect H02S connector I Yes Measure resistance between HTR GND and VPWR at sensor 1 con...

Page 438: ...GINE 6 CYL ENGINE Signal I I I Wire Color Test Pin VPWR R 71I97 I SIG RTN f GYIR 91 H02S SIG 11 GYILB I 60 i H02S HTR 11 GND RIW 93 H02S SIG 12 RILG 35 H02S HTR 12 GND WIBR I 95 H02S SIG 21 RIB 87 H02...

Page 439: ...Go to next step Install fuel pressure gauge Verify vacuum source to fuel pressure regulator If engine will start Recordfuel pressure at dle Increase engine speed to 2500 rpm and maintain for One N Per...

Page 440: ...p Crank or start engine Does test lamp have a dim glovv while cranking or running engine 1 75 4 100 I 2 101 5 73 3 74 6 99 Is resistance between 11 O 18 0 ohms Key OFF Leave PCM disconnected Disconnec...

Page 441: ...during or at the end of self test I 7 1 Yes Go to next step Replace H02S Go to step 25 Yes Go to next step I I Repair open in H02S SIG or SIG RTN circuit Go to step 25 Yes Go to next step I Repair sh...

Page 442: ...nectvacuum hose and H02S connector Go to next step Replace H02S and reconnect vacuum hose Go to step 25 Key OFF Leave suspect H02S disconnected Disconnect any vacuum hose from vacuum tree Start engine...

Page 443: ...DE H02S LOCATION ENGINE 6 CYL ENGINE H02S 11 H02S 12 INJECTORS 1 CYLINDERS PIN WIRE COLOR Signal Wire Color Test Pin VPWR R 71 97 SIG RTN GYIR 91 H02S SIG 11 A GYILB 60 H02S HTR 11 GND R W 93 H02S SIG...

Page 444: ...1 Go to next step Yes Replace H02S Go to step 8 R open clrcult Go to step 8 Go to step 7 Go to next step Remove breakout box and reconnect PCM Go to next step l PCM Go to step 8 Leave PCM and H02S di...

Page 445: ...t e p Key OFF I Yes Install breakout box leave PCM d sconnected Disconnectsuspect H02S connector For DTC P1128 H02S 11 21for upstream H02S Measure resistance between H02S SIG test p n at No breakout b...

Page 446: ...est Pin 1 Signal H02S SIG 12 RILG H02S HTR 12 GND H02S SIG 21 RIB Wire Color I H02S HTR 21 GND I YlLB 1 94 I INJECTORS 1 CYLINDERS PIN X WIRE COLOR I I 3 74 i BRN I I VIEW FROM PIN SIDE GND TO PCM 71...

Page 447: ...between PCM power distribution box and chassis ground greater than 1 power relay and fuel pump relay 10 5volts Go to step 23 I Key OFF Yes Go to next step Measure resistance between VPWR pin and FUEL...

Page 448: ...o circuit Go to step 23 Yes Go to next step Repair open in fuel purnp ground circuit Go to step 23 Key OFF Leave fuel pump and inertia fuel pump shut off switch disconnected Is resistance of power to...

Page 449: ...link connector Key ON engine off Wait five seconds Access FPF PID and observe PID while erformina the following Shake wiggle bend FP circuit between PCM and fuel pump relay or VPWR circuit between PC...

Page 450: ...MONITOR POWER TO PUMP TEST PINS LOCATED ON BREAKOUT BOX INERTIA FUEL SHUT OFF SWITCH B I TEST PIN 80 LB O FP VIEW FROM PIN SIDE FUEL PUMP RELAY CONNECTOR 000 FUEL PUMP RELAY C ONNECTOR TEST PIN 71 0...

Page 451: ...n the suspect Injectortest pin and VPWR test pins 71 97 at Go to step 7 In plnpolnt test for P0171 P0172 breakout box PO174 P0175 P113O P1131 P1132 P1150 G y U Test Prn Test Prn 1 75 4 100 P1151 P1152...

Page 452: ...ground less than 5 0 ohms Repair open in PWR GND circuit Go to step 10 Key OFF Leave CMP disconnected Installbreakout box leave PCM disconnected Is resistance between CMP sensor connector terminal CID...

Page 453: ...836 C2 4 0L CAMSHAFT POSITION SENSOR ICMP TEST PIN 51 1 TEST PIN 103zJ f PWR GND FROM POWER RELAY TEST PIN 71 3 T P VIEW FROM TEST PlNS LOCATED ON BREAKOUT BOX I TEST PIN 97 VPWR I SHIELD 3 0L HALL DE...

Page 454: ...No stall Key OFF Disconnect DPFE sensor connector Key ON engine off Measure voltage between DPFE SIG at DPFE sensor connector and chassis ground Is voltage greater than 10 5 volts Key OFF Disconnect D...

Page 455: ...pair short between DPFE SIG and VREF VREF test pin 90 at breakout box I c rcult Is resistance greater than 10 000 ohms7 I Go to step 32 I Key OFF Yes Go to next step Leave DPFE sensor connector discon...

Page 456: ...R PID indicate a fault in DPFE sensor Key OFF Disconnectvacuum hoses at EGR valve and plug hose Connect vacuum pump to EGR valve Start engine and run it at idle Access DPFEGR PID and RPM PID Key ON en...

Page 457: ...test pin 47 at breakout box and N R open EVR EVR arcuit at EVR solenold connector less than 5 0 Go to step 32 ohms Yes Replace PCM Reconnect PCM and EVR connectors Go to step 32 I IDisconnectvacuum h...

Page 458: ...1 volt in less than 3 seconds Does DFREGR PID indicate a fault in DPFE sensor Visually inspect both hoses for reversed connection at DPFE sensor or at orifice tube assembly Go to step 15 lnspect both...

Page 459: ...cuum hoses at EGR valve and plug hoses Connect vacuum pump to EGR valve Start engine and run it at idle Access DPFEGR PID and RPM PID Slowly apply 5 10 in Hg of vacuum to EGR valve and hold it for 10...

Page 460: ...usual wear carbon deposits bindingand other damage Go to step 13 I Reconnectvacuum hose 1 1 Go to next steo EGR vacuum hose connected Run KOER self test Is KOER DTC PO402 output or unable to run KOER...

Page 461: ...ross EVR solenoid No stalling engine and releasevacuum Repeat several times while observing DPFEGR PID DPFEGR PID voltage should increaseas valve begins to open and returnto initial voltage as Replace...

Page 462: ...nation and excessive 1 water absorption Inspect EGR vacuum hose for possible blockage or pinching Is EVR solenoid vent or filter contaminated or vacuum line plugged Yes Repair or replace EVR solenoido...

Page 463: ...N engine off j 1 Yes Go to next step Is voltage between DPFE SIG circuit at DPFE sensor I connector and battery ground terminal greater than 10 5 volts j No Go to Pinpoint Test VREF I 1 Yes Replace PC...

Page 464: ...ess than 5 0 ohms Key ON engine off Access DPFEGR PID Observe DPFEGR PID while performing the following Lightly tap on DPFE sensor Wiggle DPFEsensor connector and vehicle harness Is a fault indicatedb...

Page 465: ...ext step Is there a fault detected in the hose DPFE SENSOR 1 Key OFF j Yes Replace DPFE sensor Disconnect pressure hoses at DPFE sensor I Go to step 5 Connect a hand vacuum pump to downstream plckup m...

Page 466: ...97 at breakout box Measure resistance between EVR test pin 47 and PWR GND circuits GND test pins 241103 at breakout box Go to step 6 Is each resistance greater than 10 000 ohms Key OFF Yes Leave PCM...

Page 467: ...d by abnormal engine op ration upstream of catalyst restrictions 0 8 page FT 156 Go to next stem 1 Diagnostic trouble 1EVAPORATIVE EMISSION EVAP CANISTER PURGE SOLENOID code No PO443 Symptom EVAP cani...

Page 468: ...GYN EVAP SIG CANISTER PURGE I SOLENOID CONNECTOR Key OFF Install breakout box leave PCM disconnected necessary Measure resistance between EVAP SIG test pin 67 and Go to next step VPWR test pin 71 97 w...

Page 469: ...out box Measure resistance between VSS and VPWR test pin 71 at breakout box Is each resistance greater than 500 ohms Key OFF Measure resistance of VSS Is resistance between 190 and 250 ohms I Check fo...

Page 470: ...r leaks detected Cracked or punctured intake air tube loose air intake system IAC gasket EGR gasket PCV connectors and hose vacuum tubes Yes Go to next step I No I Repair open In IAC S I C circuit Go...

Page 471: ...wires Go to step 5 Is wiring too close to ignitioncomponents or wires 1 NO GOto next step 4 Disconnect breakout box and reconnect all components Cycle ignition switch on and off 40 times Key ON engine...

Page 472: ...eck for damaged or pushed out pins corrosion or loose wire Repair or replace as necessary Install breakout box leave PCM disconnected Does voltage between BOO test pin 92 and PWR GND test pin 76 or 77...

Page 473: ...o Replace the CPP switch Is resistance less than 5 0 ohms a 9 Section H Go to step 6 Install breakout box leave PCM disconnected Is there continuity between CPP SIG test pin 64 at breakout box and the...

Page 474: ...There is an open VSS circuit and a DTC is not output 3 4 Theonlyway a DTCPI000canberemovedfrom memoryiswhen alltheOBDI Imonitorshave successfully completed during normal vehicle operation Performa sh...

Page 475: ...FT ON BOARD DIAGNOSIS SYSTEM DRIVE INSTRUCTIONS OVER TIME I...

Page 476: ...Memory DTCs present Key ON engine off Was voltage between B circuit a t DLC and engine block ground greater than 10 5volts Yes Go to next step No Repa r open In data llnk connector B clrcuit Go to ste...

Page 477: ...e 4 w 1997 B series BETM j Go to next step Will engine start after Continuous Memory is cleared Is DTC P I260 still present Returnto Troubleshooting Guide number 5 to service No Start condition m pag...

Page 478: ...bar Key ON Activate KOEO self test Is DTC P I390 present Key OFF DoesOCT ADJ connector or PCMconnector have a poor connection 1 Yes 1Go to next step IOBD I1system OK Go to step 6 1z tzff connector 5 K...

Page 479: ...OFF Dlsconnectvacuum hose at both ends of EVAP canlster purge solenold Install hand held vacuum pump to Intake man fold vacuum s de of soleno d D sconnect solenold connector Apply 16 n Hg 53 kPa of va...

Page 480: ...n in VPWR circuit and VPWR circuit at sensor connector lessthan 5 0 Go to step 15 ohms Key OFF Disconnect purge flow sensor and EVAP canister purge solenoid connectors Measure resistance between EVAP...

Page 481: ...5 volts No I Unable to duplicate andlor identify fault at this No I G to step 1 Yes Repair short between PF SIG and VPWR j circuit I Go to step 13 No I Replace PCM Go to step 13 I and vehicle harness...

Page 482: ...RD DIAGNOSIS SYSTEM FT FROM PURGE FLOW POWER SENSOR PF RELAY TEST PIN 71 0 CONNECTOR TEST PIN 97 R VPWR TEST PIN 11 6BILG PF SIG TEST PIN a 24 51 76 77 103 PIN 3 TEST PINS LOCATED ON BRlfAKOUT BOX MF2...

Page 483: ...ge between WAC test pln 69 at breakout box and chass s ground less than 1 0 volt7 Key OFF D sconnect scan tool or NGS Leave PCM and WAC relay d sconnected Measure reslstance between WAC test pln 69 an...

Page 484: ...lre to both terminals at N C cycllng swltch connector Turn N C sw tch on Connect scan tool or NGS to data llnk connector Access Output Test Mode Turn all outputs off lnspect WAC clrcult for short to g...

Page 485: ...ep Adjust screw position page FT 146 Go to next step Go to next step Yes Check TP sensor I Remove cables from throttle body Does throttle rotate freely without sticking binding or grabbing condition K...

Page 486: ...ss these checks Yes Returnto Diagnostic Index to check other driveability symptoms Replacethrottle body Go to step 11 Key OFF Disconnect IAC solenoid Installbreakout box leave PCM disconnected Isthe r...

Page 487: ...damage or defects If OK replace IAC valve If not OK repair or replace throttle body Go to step 6 Key OFF Disconnect ISC solenoid Install breakout box leave PCM disconnected Is the resistance greater...

Page 488: ...SIG test pin 31 YILG and between PSP switch connector terminal SIG RTN GYIR and SIG RTN test pin 91 GYIR Yes No Yes No Yes Key OFF 1 Yes GOto next step Is the resistance greater than 10 000 ohms betw...

Page 489: ...cuits at TP sensor connector Is voltage between4 0 and 6 0 volts Yes Replace DPFE sensor No Go to step 7 Key OFF DisconnectTP sensor connector Install breakout box leave PCM disconnected Key ON engine...

Page 490: ...0 ohms 14 Key OFF Connect PCM to breakout box Measure resistance between SIG RTN test pin 91 and PWR GND test pins 51 76177 103 at breakout box Is each resistance less than 5 0 ohms 15 i Key OFF Disc...

Page 491: ...tionunlessinstructedto do so Remove all cables from throttle body linkage Removeclean air tube from throttle body andverifythere is no foreign material obstructing throttle plate Verify that the throt...

Page 492: ...control solenoid will be fully open causing high idle 6BUOFT 096 IDLE AIR CONTROL SOLENOID Inspection 1 Connect scan tool or SST NGS to data link connector Access IAC PlD and check the IAC PID values...

Page 493: ...injectors at a constant pressure Fuel is metered and injected into the intake manifoldaccordingto injectioncontrolsignalsfrom the PCM This system consistsof the fuel tank fuel pump fuel filters pressu...

Page 494: ...f injury or fire 1 Connect the SST to the fuel pressure relief valve SchradeP valve located on the fuel distribution pipe 2 Place the SST drain hose in a suitable container For inspectionof PCM termin...

Page 495: ...uel pressure Fuel pressure 240 280 kPa 2 5 2 8 kgf cm2y35 40 psi Zero or pressure low Checkthe fuel pump Referto page FT 151 If as specified the fuel line or fuel filter might be clogged or MF1038 A 6...

Page 496: ...pump monitor signal circuit has an open or short Diagnostic Trouble Code No P0230 PO231 or MF1038 A 6BUOFT 202 PO232 is output If the circuit is shorted the fuel pumpwill not operate and the engine wi...

Page 497: ...l inoperative inspect fuel pump ground circuit as follows GROUND TERMINAL VlEW FROMERMINALSlDE I INERTIAFUEL HEATFR 1 SHUTOFFSWITCH CASE LOCATEDUNDERTHE INSTRUMENTPANEL TO THERIGHTOFTHE BUTTON TRANSMI...

Page 498: ...heck Installthe fuel pumprelayand listenfor clickingof the fuel pump relay while cranking the engine 4BUOF3 139 Continuity inspection 1 Measure resistancebetweenpins 85 and 86 at the relay Specificati...

Page 499: ...regulator If the fuel line pressure decreases when vacuum increases check vacuum hose and vacuum source High pressure inspection 1 Connect the SST 2 Disconnect the fuel return line from the fuel rail...

Page 500: ...butor unless it is necessary 6BUOFT 210 I I MF1047 A 4BUOF3 146 Note Referto Section F1for 2 3L Section F2for 3 OL or Section F3 for 4 OL for Injector Removal1 Installa tion procedure Injector resista...

Page 501: ...ne 5 Start the engineand placethe transmissioninto neutral 6 Graduallyincreasethe enginespeedto 2000 rpmwhile observing the vacuum gauge 7 Decreasethe engine speed to idle while observing the vacuum g...

Page 502: ...Block the PCV valve opening 4 Verify that vacuum is felt 5 Remove the PCV valve 6 Blow through the valve from port h and verify that air comes out of port B 7 Blow through the valve from port B and ve...

Page 503: ...egulator Solenoid Ifthe EGRvacuum regulatorsolenoidor circuithasanopenor short DiagnosticTroubleCodeNo P1409 is output If the circuit is open no driveability symptom will be noticed If the circuit is...

Page 504: ...idlewith the transmissionin neutral 5 Observe the idle speed 6 Connect a vacuum pump to the EGR valve and slowly apply vacuum Specification 17 34 kPa I27 254 mmHg 5 1 0 inHg 7 Verify that the idle spe...

Page 505: ...PCM using an input signal from the purge flow sensor 5BUOF3 114 EvaporativeEmission Canister Purge Solenoid Valve If the evaporative emission canister purge solenoid valve or circuit has an open or s...

Page 506: ...operating temperature 2 Run the engine at idle 3 Disconnectthe vacuum hose from the evaporativeemis sion canister purge solenoid leading to the evaporative emission canister 4 Check that no vacuum is...

Page 507: ...anister purge solenoid Resistance 30 90 ohms 7 If vacuum operation or resistance are not as specified replace the evaporative emission canister purge sole noid PURGE FLOW SENSOR PFS Inspection 1 Disco...

Page 508: ...ed replace the fuel vapor valve A 0 1 MF1055 A 4BUOF2 160 DECHOKECONTROL SYSTEM 2 3L ONLY DESCRIPTION To facilitate starting the engine when the spark plugs becomefouled such as when the engine is flo...

Page 509: ...ngine starts Throttle valve fully open Overheating PREPARATION SST Purpose Improvedidle Improveddriveability Preventengine from overheating 5 7 N m 51 71 KgCcm 44 62 in lbf POWERTRAINCONTROL MODULE PC...

Page 510: ...TR sensor to PCM Key ON Transm sslon range Hot Idle An sensor TR1 1 Drlvlng48 km h 30 mph input _ 11 5V T Drlvrncj88 km h 55 mph Key ON Hot Idle Open or short from purge I Purge flow sensor Dr vlng 4...

Page 511: ...e Input sensor approx 0 6V PID 120 200 F Open Or short ECT to PCM Key ON 39 Intake alr temperature H o t 2 e Input IAT sensor Drlvlng 48 km h 30 mph 2 ov PID 50 1200F Open or short from IAT to 2 1V PC...

Page 512: ...sensor 11 front Englne runnlng at operating temperature 64 1 Clutch pedal pos t on IUtCh pedal depressed 0 1 v Open or short from CPP iMT CPP swltch In ut 1 I Clutch pedal released T 5V PID DRIVE swit...

Page 513: ...cuit Open or short from coll 3 to PCM Constant Constant 78 Output A TClL always ON Lamp lllumlnated Below 1 O V PID ON Short circu t from TClL to 79 AT1 Output Transmission control indicator lamp TCIL...

Page 514: ...circu t from Input 11 FRT RT Engine runnlng at normal 1 sensor to PCM I operating temperature PID ON Contaminatedsensor K Y ON d P l Heated oxygen sensor Open or short circuit from 21 FRT LFT Engine r...

Page 515: ...PID Valves Sensors I Inputs1 Actuators IOutputs I units Hot Idle 30 rnph 55 rnph Measured1PID LOAD 42 55 24 30 30 38 0FF OFF OFF 0 760 850 0 1560 21 00 I FUELPWI LONGFTl L_ SHRTFT2 0 6 6 6 6 YO I 6 6...

Page 516: ...hort from TR sensor to PCM Transmission range p d l e t sensor TRI Driving 48 km h 30 mph 1 Driving 88 kmlh 55 mph 11 5V 1 Key ON 1 1 1V I Open or short from purge flow sensor to PCM Purge flow sensor...

Page 517: ...rom TFT amb ent temperature I temperature TFT to PCM Input Transm ss on overheat operatingtemperature cond t on p y ON Heated oxygen 1 OV Open or short from sensor 12 rear Englnerunningat operating Be...

Page 518: ...natedsensor operating temperature Switch at 0 45V seconds 1 Park 1 4 23 4 68V 1 PID PARK adjustment 2 09 2 31 V sensor to PCM Second 1 39 1 53V 0 68 0 76V Transmission range TR sensor Clutch pedal pos...

Page 519: ...t from TClL to 79 Transmission control PCM AT nd cator lamp TCIL PCM malfunct on Fuel pump ON Fuel pump OFF Output I Lamp not lllumlnated PID ON Open c rcuit from fuel PID OFF pump relay to PCM B PID...

Page 520: ...from sensor to PCM operating temperature 0 3V Contaminatedsensor I I Key ON Heated oxygen Open or short circuit from sensor 21 FRT LT I Engine running at normal sensor to PCM I operatingtemperature Co...

Page 521: ...1 VBAT I VBAT VBAT VBAT DCV I I I 1360 1490 1 1560 2100 1 RPM 4 0 6 7 1 8 1 12 2 1 rnS FUELPW2 HTR11 HTR12 LONGFTl LONGFT2 FT I76 Units KOEO Hot Idle 30 mph 55 mph MeasuredI PID 4 0 6 7 j 8 1 12 2 I...

Page 522: ...ph k Driving 88 krnlh 55 rnph I Key ON Open or short from purge Purge flow sensor Drivirig48 kmlh 30 mph 1 7V flow sensor to PCM I I n 88 krn h 55 mph 1 8V Flash EPROM power 1Key ON ISUDD V 1 Open or...

Page 523: ...from TFT temperature TFT A to PCM sensor Transmiss on fluld at nor Transmlss on overheat rnal operating temperature approx 1 1V I condit on Engine coolant I Engine at operating 38 1 temperature ECT t...

Page 524: ...ower ground Ignition coil 2 53 Output Heated oxygen Switch rich to Open or short from sensor 11 front ELunning operating temperature Xm d lean 3 seconds every 1Contaminated S IISO to PCM sensor Park S...

Page 525: ...trol AT indicator lamp TCIL PCM malfunction output j 1 Lamp not illuminated B PID OFF 1 TClL never ON i Open circuit a Output I 80 Fuel pump ON Fuel pump relay I Fuel pump OFF PID ON Open c rcult from...

Page 526: ...B Open or short circuit O V from BOO to PCM 93 Heated oxygen Open or short circuit Input sensor 11 front Engine running at normal from sensor to PCM I 1 operatingtemperature 0 1V Contaminatedsensor H...

Page 527: ...3 0 4 1 MT I w 1 OFF OFF I 1 OFF OFF OFF ON r 0 760 790 1 1230 1380 1820 1930 I RPM MeasuredIPID Valves I Units KOEO Hot Idle 30 mph 55 mph Measured IPID I FUELPWl I 1 0 3 4 4 4 6 9 5 7 8 4 mS FUELPW2...

Page 528: ...als of the relay NC 8 7 Specification B Battery positivevoltage EEC PWR FUSE PCM MEMORY POWER If the EEC PWR fuse circuit has an open or short Diagnostic Trouble Code No F 0603 PI605 is output If the...

Page 529: ...mass air flow sensor connector 2 Remove the mass air flow sensor 3 Check for damage of the sensor 4 Reconnect the mass air flow sensor 5 Connect the SST NGS to the data link connector 6 Turn the ignit...

Page 530: ...occur Inspection 1 Connect the SST NGS to the data link connector 2 Turn the ignition switch ON 3 Select PIDIDATA monitor and Record function on NGS I 1 6 6 7 A Select TPS to monitor SIGNAL 4 Rotate t...

Page 531: ...f 6BUOFT 252 Inspection 1 Disconnect the engine coolant temperature connector 2 Check for damaged or pushed out pin s corrosion and loose wires 3 Reconnectthe sensor connector 4 Connect the SST NGS to...

Page 532: ...ector 2 Check for damaged or pushedout pin s corrosion and loose wires 3 Reconnect the sensor connector 4 Connect the SST NGS to the data link connector Turn the ignition switch ON 5 Access IAT PID an...

Page 533: ...resistance 5 30 ohms 3 If not as specified replacethe heated oxygen sensor s 6BUOFT 259 Removal 1 Installation 1 Disconnect the heated oxygen sensor connector 2 Remove the heated oxygen sensor 3 Inst...

Page 534: ...Disconnect the clutch pedal position switch connector 2 Connect an ohmmeter to the switch as shown 3 Check the continuity of the switch betweenthe terminals as shown Specification I Pedal 1 2ontinuity...

Page 535: ...6BUOFT 263 Temperature 10 C 50 F 20 C 68 F 30 C 86 F 40 C 104 F 50 C 122 F TURBINE SHAFT SPEED TSS SENSOR MONLY If the turbine shaft speed sensor has an open or short Diagnostic Trouble Code No PO715...

Page 536: ...ring pressure switch 4 Start the engine and let it idle 5 Connect an ohmmeter to the switch 6 Check the continuity betweenthe terminals of the switch Specification Steering Wheel I I Continuity I I Tu...

Page 537: ...is output If the camshaft position sensor circuit fails the engine may stall and not restart I CMP SENSOR HOLD DOWN CLAMP lnspection Refer to PCM specificationchart Refer to page FT 171 FT 165 Cautio...

Page 538: ...s boss engages the base notch 4 Dip gear end into engine oil to coat gear thrust washer and lower bearing loFRONT OF ENGINE CENTERLINE OF 4 ENGINE 75 for 3 OL 60 for 4 OL 5 Insert the synchronizer ass...

Page 539: ...embly 10 Connect battery ground cable Note When the battery has been disconnected and reconnected some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strat...

Page 540: ...and installation procedures only 1 INTAKE AIR SYSTEM PREPARATION COMPONENTS ACCELERATOR CABLE AND PEDAL FUEL SYSTEM PREPARATION PRECAUTION FUEL TANK FUEL FILTEZR FUEL PUMP INJECTORIPRESSURE REGULATOR...

Page 541: ...electrical connector from the following parts Mass air flow sensor Intake air temperature sensor Throttle position sensor Idle air control solenoid 2 Disconnectaccelerator cable Refer to page F1 5 3 R...

Page 542: ...Inspect for damage 6 Fuel injector 3 Throttle body 7 Intake manifold 4 Upper intake manifold Installation Note page F1 4 Inspection page F1 4 Inspection page F1 4 Installation Note page F1 4 6BUOF1 0...

Page 543: ...manifold and hand tighten all the bolts and stud 3 Tighten the intake manifold bolts and stud in the order shown to the specified torque l a FRONT OF ENGINE I FRONT OF ENGINE MF1573 A 5BUOF1 007 Tigh...

Page 544: ...ry 3 Install in the reverse order of removal Accelerator Cable Inspection Adjustment 1 Verify that the throttle valve is fully closed 2 lnspect the cable for restrictions 3 Depress the accelerator ped...

Page 545: ...efueldistributionpipe 2 Place the SST drain hose in a suitable container 3 Depressthe pressurerelief button untilthe pressureis released Alternate method 1 Disconnect the inertia fuel shutoff switch 2...

Page 546: ...ames away from the fuel area Use new O rings 1 Remove in the order shown in the figure referring to Removal Note 2 Install in the reverse order of removal I 2 0 3 0 2 1 3 1 15 22 GASKET REPLACE 2 0 3...

Page 547: ...nect the fuel return line using the SST EXHAUST SYSTEM COMPONENTS Removal 1Inspection1Installation 1 Remove in the order shown in the figure referring to Removal Note 2 Check all parts and repair or r...

Page 548: ...erioration and restriction Removal Note page F1 10 2 Three way catalytic converter InstallationNote page F1 10 Inspectfor deteriorationand restriction 5 Center bracket and insulator assembly 3 Exhaust...

Page 549: ...acket and insulator assembly with a nut and bolt Tightening torque 68 94 N m 6 9 9 6 kgfem 50 70 ft lbf 4BUOF1 154 1 Exhaust manifold 1 lnstall two guide pins into cylinder head holes 1 and 8 2 lnstal...

Page 550: ...d installation procedures only I INTAKE AIR SYSTEM PREPARATION COMPONENTS ACCELERATOR CABLE AND PEDAL FUEL SYSTEM PREPARATION PRECAUTION FUEL TANK FUEL FILTEER FUEL PUMP INJECTOR PRESSURE REGULATOR EX...

Page 551: ...ccelerator cable Refer to page F2 7 3 Remove in the order shown in the figure referring to Removal Note 4 Inspect all parts and repair or replace as necessary 5 Install in the reverse order of removal...

Page 552: ...move the ignition coil and bracket assembly and the ignition coil support bracket 5 Disconnect the throttle position selisor and air intake temperature sensor connectors 6 Removethe upper intakemanifo...

Page 553: ...Refer to Section B2 13 Remove the intake manifold and discard the gasket InstallationNote Intake manifold 1 Apply a small amount of clean engine oil to all retaining bolts and stud threads before ins...

Page 554: ...ith specified coolant Refer to Section E2 Upper intake manifold 1throttle body assembly 1 Clean and apply a small amount of clean engine oil to all bolts and stud threads before installingthem 2 lnsta...

Page 555: ...when the throttle lever is moved from fully closed to fully open 3 Verify the flatness of the upper intake manifoldlthrottle body assembly contact surface 4 Replace the upper intake manifold1throttle...

Page 556: ...eld bracket 2 Accelerator cable 5 Accelerator pedal Inspection below Inspect for damage 3 Accelerator cable bracket Accelerator Cable lnspection 1 Verify that the throttle valve is fully closed 2 Insp...

Page 557: ...el pres surefromthe fuel systemto reducethe possibilityof injury or fire 1 Connect the SST to the fuel pressure relief valve Schrader valve locatedonthefueldistribution pipe 2 Place the SST drain hose...

Page 558: ...p sparks cigarettesandopen flames away from the fuel area Use new O rings 1 Remove upper intake manifold throttle body assembly Refer to page F2 2 2 Remove in the order shown in the figure referring t...

Page 559: ...Allen head screws from the pressure regulator and discard 2 Remove the pressure regulator and discard the gasket and O ring MF1254 A 4BUOF2 138 Installation Note Pressure regulator 1 Apply a small amo...

Page 560: ...for deterioration and restriction Removal Note below 2 Three way catalytic converter InstallationNote page F2 12 Inspect for deterioration and restriction 6 Center bracket and insulator assembly 3 Fr...

Page 561: ...ut and bolt Tighteningtorque 68 94 N m 6 9 9 6 kgfem 50 70 ft lbf 4BUOF2 148 Silencer heat shield 1 Position the heat shield under the silencer body 2 Installtwo screws to the rear of the silencer Tig...

Page 562: ...iagnosis p o c e r l I Section F3 contains removal and installation proceduresonly m INTAKE AIR SYSTEM PREPARATION COMPONENTS ACCELERATOR CABLE AND PEDAL FUEL SYSTEM PREPARATION PRECAUTION FUEL TANK F...

Page 563: ...connector from the following parts Intake air temperature sensor Mass air flow sensor Throttle position sensor Idle air control IAC solenoid 2 Disconnect accelerator cable Refer to page F3 7 3 Remove...

Page 564: ...Throttle body 4 Upper intake manifold lnspection page F3 6 5 Fuel lines 6 Fuel distributor Removal Note page F3 4 I 7BUOF3 001 7 Fuel injector 8 Intake manifold Removal Note page F3 4 InstallationNot...

Page 565: ...ting bracket 2 Remove the cylinder headcovers Referto Section 83 3 Remove the intake manifold and discard the gasket Installation Note Intake manifold 1 Apply the appropriate sealant to the intersecti...

Page 566: ...he bolts in three steps in the order shown Tightening torques Step 1 4 43 N m 0 5 4 8 kgfam 3 6 ftelb Step 2 8 15 N m 0 8 1 5 kgf m 6 1 1 ft lbf Step 3 15 18 N m 1 5 1 8 kgf m 11 13 ft lbf 1 6 Install...

Page 567: ...94 UPPER INTAKE MANIFOLD lnspection 1 Check for damage and cracks 2 Verify flatness of the upper intake manifold contact sur face 3 Replacethe upper intake manifold if necessary MANIFOLD INTAKE MANIFO...

Page 568: ...3 Accelerator cable bracket 2 Accelerator cable 4 Accelerator pedal Inspection Adjustment below Inspect for damage Accelerator Cable Inspection1Adjustment 1 Verify that the throttle valve is fully cl...

Page 569: ...f switch 2 Crank the engine for 15 to 20 sec to relieve the pressure 2 Use a ragfor protection from fuel spray when disconnect ing the hoses 3 When inspecting the fuel system use the SST FUELTANK Remo...

Page 570: ...FUEL SYSTEM F3 Regular Cab I I I MF1908 A 6BUOF3 OC 1 Filler hose not shown 3 Fuel tank strap 2 Heat shield 4 Fuel tank Removal Note page F3 11...

Page 571: ...F3 FUEL SYSTEM Cab Plus 1 Filler hose not shown 2 Heat shield 3 Fueltank strap 4 Fuel tank Removal Note page F3 11...

Page 572: ...e following operation release the fuel pressure from the fuel system to reduce the possibility of injury or fire Refer to page F3 8 Always work away from sparks and open flames 6BUOF3 007 High pressur...

Page 573: ...in the reverse order of removal referring to lnstallation Note I I I I I CAB PLUS I I L I MF1149 C 6BUOF3 008 1 Shield Regular cab only 3 Fuel pump 2 Fuel pump ring 4 Fuel pump gasket lnstallation Not...

Page 574: ...page F3 8 When removingthe fuel systemcomponents keep sparks cigarettesand openflames away from the fuel area Use new O rings 1 Remove in the order shown in the figure referringto Removal Note 2 Inst...

Page 575: ...TEM TO DISCONNECT PUSH FllTlNG TOWARDS FUEL LINE 1 PRESSURE REGULATOR T 1 INSERT SST I v I SLIDE FITTING AND SST OFF OF FUEL LINE n Removal Note Fuel lines Disconnect the fuel return line using SST as...

Page 576: ...1878 A 1 Silencer lnspect for deteriorationand restriction 2 Three way catalytic converter lnspect for deteriorationand restriction 3 Front pipe assembly lnspect for deterioration and cracks 4 Exhaust...

Page 577: ...emove the exhaust manifold from the vehicle 4BUOF3 157 Right 1 Remove the heater hose support bracket 2 Disconnect the heater hoses 3 Remove the exhaust manifold retaining bolts and studs 4 Remove the...

Page 578: ...l pumppressureand return hoses if removed 4 Installthe oil leveldipsticktube support bracket Apply the appropriatesealant to the endof the tubeto prevent an oil leak at the block 4BUOF3 162 Right 1 Cl...

Page 579: ...REGULATOR1 BRUSH HOLDER ASSEMBLY G 17 GENERATOR PULLEY AND REGULATORTERMINAL G 19 DRIVE BELT G 20 ELECTRONICIGNITION SYSTEM G 22 PREPARATION G 22 CIRCUIT DIAGRAM G 23 TROUBLESHOOTING G 30 SECONDARY IG...

Page 580: ...G INDEX INDEX I I I 2 3L ENGINE IGNITION SYSTEM...

Page 581: ...INDEX G 1 3 OL ENGINE IGNITION SYSTEM FRONT OF VEHICLE 4 OL ENGINE IGNITION SYSTEM...

Page 582: ...lation 5 High tension leads Inspection 6 Ignition coil assemblies page G 13 Removal1 Installation page G 14 7 Crankshaft position sensor Inspection page G 15 Removal Installation 8 Starter page G 17 I...

Page 583: ...ll between 4 and 25 mark ngs on belt tensioner 3 Automatic tensioner indicator must fall between 4 and 19 markings on belt tensioner El Electrical Distributorless Ignition System MG1063 G Note When th...

Page 584: ...ge G 63 TERMINAL B I Yes Go to next step Is battery positive voltage present at terminal S with ignition switch in START position TERMINAL S Yes Check wiring harness Check magnetic switch Check yoke C...

Page 585: ...warning light illuminateswhile engine running I STEP INSPECTION Is battery positive voltage correct at idle Specification14 1 1 4 7V terminal and generator warning light as page G 12 1 5 1 Discharged...

Page 586: ...G CHARGING SYSTEM CHARGING SYSTEM Note...

Page 587: ......

Page 588: ...XI34 COMMONCON MA DPHJ XI36 COMMONCON MA DPW XI39 COMMON CON DPHJ ARS X 213 IGNmONSWITCH MA SEE COMMONCONNECTORUST SECTIONX 5 0 0 I B z I z I V V I rn z...

Page 589: ...tion to warn of the following problems in the chargingsystem If a problem arises the generator warning light illuminates 1 Terminal S circuit open 2 No voltage output 3 Fieldcoil circuit open 4 Termin...

Page 590: ...step Is voltage at generator termmais correct Specifications 14 1 14 7 6 6 6 9 Yes Check wiring harness and fuse link Battery Terminal B Check wiring harness and fuse link Replace regulator or generat...

Page 591: ...nds is voltage more than specification 1 of battery after 2 minutes I Below 11 5V I Above 11 5V I I I Above 11 5V I Battery voltage with load Approximate Minimum 21 C 70 F 16 C 60 F 10 C 50 F 4 C 40 F...

Page 592: ...Place the battery in water to prevent it from over heating Warm up the battery to 5 C 41O F before charging Warning Before performing maintenance or recharging the battery turn off all accessories and...

Page 593: ...sconnect the negative battery cable 2 Remove the snowlice shield and the fresh air inlet tube 3 Removethe generator referringto Removal Note Refer to below 4 Inspect all parts and repair or replace if...

Page 594: ...Install the generator Tightening torque 40 54 N m 4 1 5 5 kgfem 3 0 4 0 ft lbf 2 Connect Terminal B wire Tighteningtorque 9 0 1 2 0 N m 0 91 1 22 kgf m 6 6 9 0 ftdbf 3 Connect the harness connector to...

Page 595: ...tallation Note I MGlO31 A 4BUOGX 020 1 Voltage regulator brushholder assembly Removal Note below InstallationNote page G 18 Removal Note Voltage regulator 1brush holder assembly 1 RemovethefourTorx T2...

Page 596: ...cap of the Terminal A screw 3 Depressthe brushes into the brush holder assembly and hold the brushes in position by inserting a standard size paperclip Insert the paperclip through both the location...

Page 597: ...the figure 2 Inspect all parts and repair or replace if necessary 3 Install in the reverse order of rernoval referringto lnstallation Note I I MG1073 B 4BUOGX 023 1 Pulley 2 Rear bracket Installation...

Page 598: ...drive belt and pulleys for wear cracks and d a m a g e Replace if necessary GBUOGX 011 Note No adjustment is necessary All engines are equipped with automatic tensioners that indicate when the drive b...

Page 599: ...RATOR AIR CONDlTlONllVG IDLER LESSN C POWER WATER PUMP 2 Onthe 3 OL engine loosenthe drive belttension by lifting thetensioner pulleyinthe clockwisedirectionand remove the old belt 3 Install the new b...

Page 600: ...he diagnostic cables may be connected with the breakout box in series with the ignition system components The ignitionsystemcan bediagnosed by placingthe correctoverlay on the breakout box and monitor...

Page 601: ...H l 2 X 213 XI007 COMMON IGNITIONSWITCH CON CLSQlflLF IRL 8 111POWERTRAINCONTROL MODULE PCM ECS X 01 ENGINECOMPARTMENTFUSE RELAYBOX DPHJ X 02 Iff FUSEPANEL MA X 114 COMMONCON ECS ECO X210 BRAKEONIOFF...

Page 602: ...EM ENGINE CONTROL SYSTEM ENGINE XI24 R ECS I SYSTEM R R I 1 DpW DPHJ R ECS R ECS R ECS R ECS R ECS R ECS IAC VALVE SOLENOID Bffl BILG WILE BWP DPMI DPKI 1 I ECS ECS CONTROL ENGINE 1 SYSTEM SECTIONB 2a...

Page 603: ...CH MA 0 1009 FUELPUMPIFUELGAUGE SENDER RL El002 VEHICLE SPEEDSENSOR VSS ECE u X 01 ENGINECOMPARTMENTFUSEIREW BOX DPHJ X 02 I P FUSEPANEL MA X 114 COMMONCON ECS ECE x124 COMMONCON ECS DPHJ X 129 COMMON...

Page 604: ...TROL R ECSI SYSTEM B 105 SECTION B 6 MASSAIR FLOW CONTROL FLoW MAF SENSOR IAC VALVE SENSOR 8 105 SOLENOID BR LB T B LG O T W BWY ECS ECS ECS ECS ECS ECS 1 ECS ECS X 114 BAG GYN ESC ECS Q B 4a 3 OL IGN...

Page 605: ...ILF RL SEE COMMON CONNECTOR USI SECTION x 8 111 POWERTWIN CONTROL MODULE PCMJ ECS m X 01 ENGINE COMPARTMENT FUSVRELAY BOX DPW X 02 IIP FUSE PANEL MA X 114 COMMON CON IECS ECE X 210 BRAKEONIOFF BOO SWI...

Page 606: ...B W T 8 LGIO T W BWY ECS ECS ECS ECS ECS ECS 1 ENGINE CONTROL SYSTEM BNV B w BAN BNV B W X 134 COMMONCON MA OPW SEE COMMONCONNECTOR UST SECTIONX...

Page 607: ...TEM G El High Data Rate Diagnostic Cabl 49 UNO1 057 For 2 3L 3 OL and 4 OL EI HIGH DATA RATE IGNITION DlAGNOSTlC I CABLE IDM PUSH BUITON SPOUT PUSH B m O N DRIVER TEST OPENS IDM CIRCUIT S p I R C U I...

Page 608: ...ct Scan Tool or NGS from DLC Inspect PCM for damaged or pushed out pins corrosion or loose wires Install 104 pin breakout box and connect PCM Caution Do not use an incandescent lamp to check crankshaf...

Page 609: ...s repair short in CKP circuit to power 1Yes 1 Replace PCM DisconnectPCM from 104 pin breakout box Crank the engine and measurevoltage between Pin 21 and Pin 22 at 104pin breakout box Is settled AC vol...

Page 610: ...ctor Yes Replace CKP sensor High resistance Yes Replace CKP sensor No output from sensor No I NO 1 Repair or replace damaged parts Check connectors repair open in CKP circuit I Yes Low bias voltage fa...

Page 611: ...tion CKP sensor shield connector Are spark plugs and high tension leads OK Warning Never connect PCMto 104 pin breakout box when performing El diagnostics Key OFF Yes No Yes No Yes Install El diagnost...

Page 612: ...step 23 Caution 2 3L and 3 OL When performing this test procedure remove El diagnosticconnector from CKP sensor and vehicle harness Reconnectvehicle harness to CKP sensor Connect El diagnostic harness...

Page 613: ...eater than 2k ohms connector Measure resistance betweenJ7 and J10 at 60 Measure resistance between J7 and J10 at 60 short in coil circuit to ground pin breakout box Is resistance greater than 1O k ohm...

Page 614: ...easure voltage between Pln 104 at 104 ptn I breakout box and J7 at 60 pln breakout box No Check connectors repalr open ncod c rcult I Is voltaae areater than 10 0volts Use 2 3 i El H gh data rate 8 ov...

Page 615: ...m vehicle harness connector Measure resistance between J7 and J10 at 60 pin breakout box Is resistance greater than 1O k ohms Key OFF Disconnectcoil from coil tee leave El diagnostic harness connected...

Page 616: ...breakout box Is voltage greater than 10 0 volts Key ON engine OFF Measure voltage between J6 and J7 at 1 60 pin breakoui box Is voltaae areater than 10 0 volts Reinstall plugs and leads Go to step 44...

Page 617: ...Disconnect PCM from vehicle harness connector No Replace right coil pack I I Measure resistance betweenJ7 and J3 at 60 in breakout box Yes No Check connectors repair short in coil circuit to ground Re...

Page 618: ...lgnition Pickup PIP pulses occurred inside PCM resulting in a possible engine miss or stall Check for the following Loose wires connectors Arcing secondary ignition components On boardtransmitter Note...

Page 619: ...ty of operating in a multi strike mode the spark plugs are fired four 4 strikes per firing The operating modes are limited to about 1500 rpm Although the PCM provides these operating modes the PCM mus...

Page 620: ...k the following High tension lead connections not firmly connected Spark plug gap Refer to page G 43 Resistanceof high tension leads Referto pageG 46 Result 5 Consistently low spark plug firing voltag...

Page 621: ...from which they were removed 3 Apply anti seize compound or molybdenum basedlubri cant to the spark plug threads 4 Tighten the spark plug to the specified torque Tightening torque 2 3L13 OL 9 20 N m I...

Page 622: ...1 Remove the spark plug 2 Connect the spark plug to a high tension lead 3 Hold the high tension lead and spark plug with insulated pliers 5 10mm 0 20 4 39 in from a ground 4 Crank the engine and verif...

Page 623: ...IDENTIFIED BY BLACK DRY FLUFFY CARBON DEPOSITS ON INSULATOR TIPS EXPOSED SHELL SURFACES AND ELECTRODES CAUSED BY WRONG TYPE OF FUEL INCORRECTIGNITIONTIMING OR ADVANCE TOO HOT A PLUG BURNT VALVES OR EN...

Page 624: ...ng to Removal Note 3 Install in the reverse order of removal referring to Installation Note I111 11p I _ 1 MG1092 A 5BUOGX 027 1 Ignition coil Removal Note page G 48 Installation Note page G 48 High t...

Page 625: ...TRONIC IGNITION SYSTEM I I MG1093 A 5BUOGX 028 1 Ignition coil Removal Note page G 48 InstallationNote page G 49 I I MG1047 C 5BUOGX 029 1 Ignition coil Removal Note page G 48 Installation Note page G...

Page 626: ...on coil 5BUOGX 031 lgnition coil 4 OL 1 Disconnect the harness connector from the coil 2 Disconnectthe high tensionleads by squeezingthe lock ing tabs to release the coil boot Note On vehicles equippe...

Page 627: ...nitioncoiland install the bolt Caution Connectthe vacuum hosesto the original position on the EGR vacuum regulator Tightening torque 8 1 2 N m 0 8 1 I kgf m 6 44 ft lbf 4 Connect the harness connector...

Page 628: ...er than 0 4 volt 4 If voltage is not as specified go to procedure 5 If voltage is OK crankshaft position sensor is OK 5 Key OFFand disconnect the PCMfrom the breakout box 6 Crank the engine and verify...

Page 629: ...Remove the generator 3 Drain the cooling system 4 Remove water outlet tube 5 Disconnectthe crankshaft position sensor harness connector 6 Removethe crankshaft position sensor bolt 7 Pry the crankshaft...

Page 630: ...0L 1 Disconnect the negative battery cable 2 Raise vehicle on a hoist 3 OL only 3 Disconnect the crankshaft position sensor harness connector from the wiring harness 4 Remove the crankshaft position...

Page 631: ...3 Installthe water outlet tube with a new O ring and install the bolts Tightening torque 10 5 N m 1 1 kgfem 8 ft lbf 4 Installthe generator 5 Fill the cooling system 3 0L 14 0L 1 Positionthe cranksha...

Page 632: ...R WIO W ANTI THEFT ppppp A 169 GENERATOW REGULATOR ARS A48 STARTER MOTOR GENERATOR REGULATOR ARS W1 ENGINE COMPARTMENTFUSEIRELAY BOX DPHJ X02 IIP FUSE PANEL MA X03 RELAY BOX 1 MA X 124 COMMONCON ECE E...

Page 633: ......

Page 634: ...urn check the voltage at Terminal B and Terminal S with the ignition switch in START and the clutch pedal depressed MT or transmission in park or neutral AT 4 If the voltage is more than 8V remove and...

Page 635: ...ure the connector locks in position with a notable click or detent 3 Installthe Terrninal B nut Tightening torque 11 13 N m 1 l 1 3 kgf m 91 122 in lbf 4 Replace the red magnetic switch safety cap 5BU...

Page 636: ...o Assembly Note MG1056 C 1 5BUOGX 047 1 Magnetic switch 7 Lever and housing seal Inspection page G 60 8 Front cover 2 Rear cover 9 Stop ring and retainer 3 Brush holder assembly 10 Pinion and reductio...

Page 637: ...reductiorigear Partially fill the rear cover housing bearing bore with grease approximately 114 full Install the pinion and reduction gear assembly in the housing making sure to line up the bolt hole...

Page 638: ...0 N m 51 102 kgfecm 44 48 in lbf 11 Install the starter drive plunger lever cover and tighten the screw Inspection Magnetic switch 1 Remove the magnetic switch from the starter 2 Check for continuity...

Page 639: ...pring if not as specified Brush If a brush is worn almost to or beyond the wear limit replace all of the brushes Brush length 16 8mm 0 66 in Armature 1 Check for no contirluity betweenthe commutator a...

Page 640: ...d replace the armature I 1 Note 1 Do not wash the armature with solvent MGlO26 A 4BUOGX 105 Internal gear and planetary gears Check for wear and damage Replace as necessary 4BUOGX 106 Yoke NORMALWEAR...

Page 641: ...er to Section K Iftheclutchpedalis notdepressedduringstarting battery power will not be supplied to the starter and it will not operate 4BUOGX 109 Inspection 1 Disconnect the clutch pedal positionswit...

Page 642: ...TALLATION H 7 CLUTCH MASTER CYLINDER H 8 REMOVAL INSTALLATION H 8 AIR BLEEDING REFER TO PAGE H 4 CLUTCH RELEASE CYLINDER H 9 REMOVAL INSTALLATION H 9 AIR BLEEDING REFER TO PAGE H 4 OVERHAUL H 10 INSPE...

Page 643: ...allation Air bleeding 4 Clutch release cylinder Removal Installation Overhaul Inspection 5 Clutch release collar Inspection page H 6 page H 6 page H 7 page H 8 page H 4 page H 9 page H 10 page H 11 pa...

Page 644: ...isengagement Vibration of clutch when accelerating Clutch pedal sticking Abnormal noise Possiblecause Clutch disc facing worn Clutch disc facing surface hardened or oiled Clutchcover damaged Diaphragm...

Page 645: ...lease cylinder while applying a slight tug on the clutch pipe 2 Clean dirt and grease from around the reservoir cap 3 Remove the cap and diaphragm and fill the reservoir to the step with the specified...

Page 646: ...ientation a bench bleed air can escape much more efficiently 1 Holdthe mastercylinder vertically with the reservoirfeed hose in the highest position on the body 2 Fill the reservoir and extend above t...

Page 647: ...lutch linkage or pedal position is required 4BUOHX 008 REMOVAL INSTALLATION 1 Remove left side plastic kick panel 2 Disconnectthe clutch master cylinder push rod by prying the retainer bushing and pus...

Page 648: ...OHX 010 1 Harness connector 3 Clutch pedal position switch 2 Plastic retainer Removal Note below Removal Note below Removal Note Plastic retainer Remove the retainer as shown in the figure I Clutch pe...

Page 649: ...5 1 161 59 8 4 11 5 N m kgf m ft Ibf MH1004 C 5BUOHX 006 1 Master cylinder push rod 5 Bolts 2 Clutch pedal position switch 6 Clutch master cylinder Removal Installation page H 7 Inspectfor fluid leaka...

Page 650: ...e If spilled wipe it off immediately 1 Disconnect the clutch pipe from the transmission using Clutch Disconnect Tool T88T 70522 A or equivalent referringto Removal Note 2 Remove the transmission Refer...

Page 651: ...while applying a slight tug on the pipe I I 1 0 0 5 c B L J H X O O Installation Note Clutch release cylinder Installthe clutch release cylinder Tightening torque 19 1 25 9 N m 1 9 2 6 kgf m 14 1 19...

Page 652: ...lGauge D87T 4201 A or equivalent 3 Havean assistantfully depress the clutch pedalandtake another measurement 4 The difference between the two readings is the total bearing travel 5 Ifthe releasecollar...

Page 653: ...s necessary 6 Remove in the order shown in the figure referring to Removal Note 7 Install in the reverse order of removal referring to lnstallation Note 8 After installation bleed the clutch system Re...

Page 654: ...ts 2 Loosen each bolt oneturn at atime ina crisscross pattern until the spring tension is released 3 Remove the clutch cover and disc Pilot bearing If removing the pilot bearing use Puller Attachment...

Page 655: ...e grease to the splines 3 Hold the clutch disc in position by using Clutch Aligner T74P 7137 K or equivalent Clutch cover 1 Align the dowel holes with the flywheel dowels and install the clutch cover...

Page 656: ...RELEASE COLLAR INSPECTION WEAR PATERN FROM WARPEDCLUTCH COVER Note The clutch release collar is a sealed bearing and must not be washed CLUTCH DISC INSPECTION Note Minor scoring or burning should be...

Page 657: ...ce or visible grease leakage replace it 1 I MH1015 B 4BUOHX 035 FLYWHEEL INSPECTION Note Minor scoring or burning should be removedwith emery paper STYLUSCONTAC FORWARD OR 1 lnspect the contact surfac...

Page 658: ...CATlONS J1 3 TROUBLESHOOTING GUIDE J1 3 TRANSMISSION OIL J1 4 lNSPE CTlON J1 4 REPLACEMENT J1 4 TRANSMISSION J1 5 PREPARATION J1 5 REMOVAL J1 5 DISASSEMBLY J1 7 INSPECTION J1 13 ASSEMBLY J1 15 INSTALL...

Page 659: ...F SERVICE SECT1 GRADE ATF DEXRONW II OR M Ill CAPACITY 2 65 LITERS 5 6 US pt 4 5 Imp pt I I MJI 133 D 5BUOJ1 009 1 Transmission 2 Transmission oil Removal page J1 5 Inspection page J1 4 Disassembly pa...

Page 660: ...11 qual ty I Wear or play of shift fork or shift rod Worn synchronizer ring Excessive longitudinal play of gears Worn bearing Worn gear sliding surface of shaft gears disengagement Worn shift fork s W...

Page 661: ...am 3 0 4 2 ft lbf REPLACEMENT 1 Remove the drain plug and washer 2 Drain the oil into a suitable container 3 Install a new washer and the drain plug Tightening torque 40 58 N m 4 1 5 7 kgf m 3 0 4 2 f...

Page 662: ...battery cable 2 Place the transmission in neutral 3 Remove the gear shift lever referring to Removal Note Refer to page JI 6 4 Raise the vehicle and support it with safety stands 5 Drain the transmiss...

Page 663: ...ectthe clutch pipe at the transmission case using Clutch Disconnect Tool T88T 70522 A or equivalent 2 Slide the white plastic sleeve toward the clutch release cylinder while applying a slight tug on t...

Page 664: ...4 Wear eye protection when using compressed air to clean components Transmission 1 Remove the shift lever boot and gear shift lever if necessary 2 Remove the control case 3 Removethe rear seal if nec...

Page 665: ...hkeverse shift rod and fork 18 Synchronizer ring 5th Inspection page J1 14 19 Countershaft lever assembly 20 5th gear needle bearing 21 5th gear secondaryshaft 22 5th gear sleeve 23 5th gear ball 24 C...

Page 666: ...the removed locknuts REVERSE RETAINING RING IDLER GEAR DIAMETER RETAINING IDLER SHAFT G Reverse idler gear 1 Remove the reverse idler gear 2 Remove the retaining ring spacer idler gear needle bearing...

Page 667: ...bolt locations Note Boltsthreadedintothe clutch releasecylinder bolt locations will bottom out and lift the front bearing cover away from the transmission case Do not remove the plastic scoop ring fr...

Page 668: ...4th Inspection page J1 14 6 Synchronizer ring 3rd Inspection page JI 14 7 3rd gear 8 Needle bearing 9 Center bearing outer race 10 Center bearing inner 11 1st gear sleeve 12 1st gear 13 1st gear needl...

Page 669: ...nt Note SST Number 49 UNO1 073 BearingCone Replacer Control Case 1 Remove the dust cover referring to Disassembly Note Refer to below 2 Remove the back up light switch and pin 3 Remove the parklneutra...

Page 670: ...the lock ball and friction device bores and seats with a clean cloth Caution Failure to cover the cover lock ball and friction device borles could result in component loss 6 Remove the Sthlreverse shi...

Page 671: ...ub Assembly 1 lnspect the clutch hub sleeve and hub operation 2 lnspect the gear teeth for damage wear and cracks 3 lnspect the synchronizer keys for damage wear and cracks 4 Measure the clearance bet...

Page 672: ...y that all parts are completely cleaned before assembly 3 Assemble partswithin 10minutesafter applyingsealant Allovvall sealantto cure at least30 minutesafter assembly before filling the transmissionw...

Page 673: ...ginal positions 3rd14th shift rods 1 Position the shift rod into the control case 2 Position the detent ball and spring into the control case spring seats 3 Compress the detent ball and spring assembl...

Page 674: ...pins Sthlreverse shiift rods 1 Position the shift rod into control case 2 Position the detent ball and spring into the control case spring seats 3 Compress the detent ball and spring assembly and pus...

Page 675: ...gear 13 Synchronizer ring 3rd 14 Clutch hub and sleeve assembly 3rdl4th 15 Spacer 16 Needle bearing 17 Retaining ring 18 Roller bearing SLEEVE BEARING C REPLACER T53T 4621 Assembly Note Secondary sha...

Page 676: ...ace toward 4th gear 2 Install the longer flange on the clutcli hub sleeve toward the 3rd gear side Note The 3rd gear synchronizer ring has three teeth cut out 120 apart from each other Directlyadjacen...

Page 677: ...Assembly 1 Assemble in the order shown in the figure referring to Assembly Note 2 Install the speedometer drive gear referring to Assembly Note Refer to page J1 28 3 Install the extension housing ref...

Page 678: ...untershaft lever assembly Assembly Note page J1 25 17 Spring 18 Detent Ball 19 Clutch hub and sleeve 5thlreverse 20 Synchronizer ring 5th 21 Shift fork assembly Assembly Note 22 Shift rod bolt 23 Spli...

Page 679: ...VER INPUT T71P 4621 6 SHAFT BEARING Make sure that the outer race is squarely posi tioned in the bore Primary shaft 1 Press the primary shaft bearing onto the primary shaft using Bearing Cone Remover...

Page 680: ...ront bearing race 5 Measure depth D of the front cover outer race bore 6 Select an adjustment shim s to maintain end play within the specified limits B A adjustmenl shim 0 05 0 15mm 0 002 0 006 in C D...

Page 681: ...ion countershaft front bearing bore 9 Tape the primary shaft splines along their entire length 10 Apply a 118 in bead of appropriate sealant to the front cover and bolt threads 11 Install front cover...

Page 682: ...and sleeve and the 5th gear synchronizer ring on the shift fork assembly Note The reference mark on the synchronizer sleeve must be installedtoward the rewerse gear side 5 Install the shift fork asse...

Page 683: ...0 0078 in REVERSE RETAINING RING IDLER GEAR DIAMETER AFTER ASSEMBLY 5 If the end play is not as specified select the proper retaining ring Reverse idler gear 1 Install the thrust washer onto the reve...

Page 684: ...4x4only Gear InstallingSpacer T88T 7025 E or equivalents 4BUOJ1 066 Locknuts Caution Do not reuse the removed locknuts 1 Remove the temporary spacer from the countershaft 2 lnstall the countershaft re...

Page 685: ...stallthe extension housingrear oil seal usingthe Exten sion HousingSeal ReplacerT61L 7657 A or equivalent Note Make sure that the oil seal drain hole faces downward Control case Install the control ca...

Page 686: ...tallationNote Refer to below 13 Test drive the vehicle and check the transmission operation InstallationNote Transmission 1 Make sure that the machined mat r g surfaces and the locating dowels are fre...

Page 687: ...2 12 MANUAL SHIFT TRANSFER CASE J2 13 PREPARATION J2 13 TROUBLESHOOTING GUIDE J2 14 REMOVAUINSTALLATION J2 14 DISASSEMBLY J2 17 INSPECTION J2 23 ASSEMBLY 52 23 ELECTRONIC SHIFT TRANSFER CASE 52 32 PRE...

Page 688: ...LITERS 2 5 US PT 2 1 IMP PT MJ1146 B 5BUOJ2 001 1 Transfer case 2 Shift lever and linkage Troubleshooting Guide page J2 14 Removal Installation page J2 10 Removal Installation page J2 14 Inspection pa...

Page 689: ...allation page J2 34 Inspection page J2 65 2 Electronic shift motor assembly Removal Installation page J2 35 Inspection page J2 65 3 Shift motor sensors Inspection page J2 65 7BUOJ2 021 4 4x4 Trarlsmis...

Page 690: ...Imp pint Tvpe ATF Mercon M Ill Note Whenthe batteryisdisconnectedandreconnected someabnormaldrivesymptomsmayoccur while the powertraincontrolmodule relearnsitsadaptivestrategy The vehicle may needto...

Page 691: ...OUTLINE...

Page 692: ...e vehicle on level ground 1 Remove the filler plug 3 Apply sealant to the threads of the filler plug Install the filler plug Tighteningtorque 19 30 N m 1 9 3 0 kgf m 14 22 ft lbf REPLACEMENT 1 Remove...

Page 693: ...smissions 4 Removethe damper from the transfer case if equipped 5 Remove the skid plate from the frame if equipped 6 Remove the transfer case drain plug and drain the transfer case fluid into a suitab...

Page 694: ...ll the transfer case drain plug Tightening torque 19 30 N m 1 9 3 0 kgf m 14 22 ftdbf 14 Add the specified amount and type of fluid Refer to page J2 6 15 lnstall the filler plug Tightening torque MJI...

Page 695: ...e vent assembly with the white mark inthe shifter notch Note The upper end of the vent hose should be 19mm 314in abovethetopof theshift leverassemblyand just below the floor pan Rubber boot and floor...

Page 696: ...s as specified Specification Maximum 3 30mm 0 13 in 4BUOJ2 018 ADJUSTMENT 1 Raise the rubber boot to accessthe top of the cam plate 2 Loosen bolts A and B one turn 3 Move the shift shaft lever to the...

Page 697: ...r Output shaft bearing replace I 49 UNOl 036 removal installationof Pinion bearing needle bearing cone replacer For removal of front output shaft bearing shaft bearing 49 UNOl 025 1 For installation o...

Page 698: ...king key Damaged cam assembly Damaged hub assembly p p p p p Loose shift linkage Worn or damaged 2W 4W lockup assembly Worn or damaged 2W 4W shift fork Loose shift linkage Worn or damaged 2W 4W lockup...

Page 699: ...llation page J2 10 Assembly page J2 23 3 Transfer case 4 Shift shaft lever Removal Note below Removal Note Transfer case 1 Support the transfer case with a transmissionjack 2 Remove the bolts 3 Remove...

Page 700: ...the shift lever assembly and just below the floor pan 4BUOJ2 025 Transfer case drain plug 1 Apply sealant to the threads of the transfer case drain plug 1 2 Tighten the transfer case drain plug Tighte...

Page 701: ...eanthetransfer caseexteriorthoroughlywith asteamcleanerof cleaningsolventsbeforedisassembly 2 Clean the removed parts with cleaning solvent and dry with compressed air Clean out all holes and passages...

Page 702: ...52 MANUAL SHIFT TRANSFER CASE...

Page 703: ...J2 21 16 Front drive sprocket 42 Shift shaft lever Disassembly Note page J2 20 Disassembly IVote page J2 22 17 Drive sprocket 43 Set screws Disassembly Note page J2 20 44 Shift shaft 18 Magnet Disasse...

Page 704: ...e sprocket and front drive sprocket Removethe chain drive sprocketandfront drivesprocket as an assembly I I MJ1020 A 4BUOJ2 034 Rear output shaft pump assembly and oil pump filter 1 Removethe rearoutp...

Page 705: ...th the input shaft against a work bench pushdown on the front adapter 3 Lift the input shaft and planet carrier from the front adapter 4BUOJ2 039 Planet carrier Separate the planet carrier from the in...

Page 706: ...ase 3 Remove the O ring from the second groove in the shift shaft Discardthe O ring 4BUOJ2 044 MJ1025 B 4BUOJ2 043 Ring gear Use a press to remove the ring gear Note Note the relation of the serration...

Page 707: ...seal Assembly Note page J2 28 28 Front adapter 29 Front adapter planet carrier and input shaft assembly Assembly Note page J2 28 30 H Lshift fork Assembly Note page J2 29 31 H L hub Assembly Note pag...

Page 708: ...driven straight into the bore SST numbers 49 F027 005 Output Shaft Bearing Replacer 49 F027 003 Driver Handle 2 Install the snap ring Oil seal lnstall the oil seal using the SSTs MJ1026 A 4BUOJ2 052 N...

Page 709: ...90 bent tang of the 4H assist spring Note Position the shift shaft lever in the 4L detent position 2 Insertthe roller intothe assist springlrollerslot of the shift cam 3 Position the middle section o...

Page 710: ...ts in the shaft Bearing sleeve Use a press and the SST to install the bearing sleeve Oil seal Installthe oil seal in the front adapter using the SSTs Front adapter planet carrier and input shaft assem...

Page 711: ...nto the rear output shaft I Oil pump drive pin height MJ1029 A 4 0 2 0 6 s Height measured during disassembly or Minimum 1mm 0 040 in 4BUOJ2 067 Rear output shaft pump assembly and oil pump filter 1 I...

Page 712: ...lO19 A 4BUOJ2 070 Bearing Install the bearing into the transfer case cover using the SSTs Transfer case 1 Apply sealant to the mating surface of the transfer case Note Move the chain cover up and down...

Page 713: ...ionof electronic shift system Worn or damaged 2W 4W lockup assembly Worn or damaaed 2W 4W shift fork Section Q Section Q J2 39 J2 39 J2 39 32 39 J2 39 Won t shift to Malfunctionof electronicshift syst...

Page 714: ...val 1 I I MN1183 A 5BUOJ2 036 1 4 4 shift control switch 2 Harness connector 4x4 TRANSMISSION SELECT RELAY Removal I Installation 1 Remove audio system Refer to Section J of the 1997 B Series BETM 2 R...

Page 715: ...able 2 Raise the vehicle and support it with safety stands 3 Remove in the order shown referringto Removal Note 4 Install in the reverse order of removal referringto InstallationNote I N m kgfm ft lbf...

Page 716: ...TION 1 Disconnect the negative battery cable 2 Raise the vehicle and support it with safety stands 3 Drain the transfer case fluid into a suitable container Note Drain the transfer case fluid before r...

Page 717: ...fer case Installation Note page J2 38 Removal Note below InstallationNote page J2 38 Removal Note Damper Remove the damper if equipped Transfer case 1 Support the transfer case with a transmissionjack...

Page 718: ...e should be 19mm 314 in above the top of the shift lever assembly MJIO I A 4 6 0 2 0 9 3 and just below the floor pan 5BUOJ2 028 Transfer case drain plug 1 Apply sealant to the threads of the transfer...

Page 719: ...steamcleanerof cleaningsolventsbeforedisassembly 2 Clean the removed parts with cleaning solvent and dry with compressed air Clean out all holes and passages with compressedair and verify that there a...

Page 720: ...52 ELECTRONIC SHIFT TRANSFER CASE OIL SEAL REPLACE...

Page 721: ...ocket Disassembly Note page J2 43 27 Magnet 28 Rear output shaft Disassembly Note page J2 20 29 Pump assembly Disassembly Note page J2 20 30 Oil pump filter Disassembly Note page J2 20 31 Oil pump dri...

Page 722: ...CASE Disassembly Note Motor connector Remove the brown wire from the motor connector Clutch housing assembly Remove the clutch housing Shift cam assembly Remove the spacer shift cam torsion spring and...

Page 723: ...Rear output shaft Assembly Note page J2 29 26 Pump assembly Assembly Note page J2 29 27 Oil pump filter Assembly Note page J2 29 28 Magnet 29 Chain Assembly Note 30 Front drive sprocket Assembly Note...

Page 724: ...ng tangs and drive tang SECOND SPRING TANG I I MJ1055 A 4BUOJ2 108 2W 4W lockup assembly and 2W 4W shift fork Install the 2W 4W lockup assembly and the 2W 4W shift fork as an assembly MJ1048 A 4BUOJ2...

Page 725: ...ing the chain cover Raise the 2W 4W shift fork while holdingthe shift rail in place Engagethe 2W 4W shift fork bushing into the shift cam Clutch coil 1 Apply sealant to the clutch coil studs and gromm...

Page 726: ...g installation 2 Apply sealant to the motor housing base 3 Loosen the motor bracket nuts 4 Install the wire harness bracket and motor assembly Tightening torque 8 1 10 8 N m 0 82 1 1 kgfsm 6 43 ft lbf...

Page 727: ...ELECTRONICSHIFT TRANSFERCASE 52 TROUBLESHOOTING Circuit Diagram...

Page 728: ...RESS TRIGGER TO START DIAGNOSTIC DATA LINK VIEW RECORDER AREAS DIGITAL MEASUREMENT SYSTEM NO VEHICLE SELECTED DESELECT CURRENT MODEL 1 I I I I SELECT ITEM AND PRESS TRIGGER TO START 3 Select SELECT NE...

Page 729: ...ICS I11 I SELECT ITEMAND PRESSTRIGGER TO START 6 Retrieve DTCs I 2 MJ1175 A Erasing DTCs 1 perform the necessary vehicle preparation and visual inspection Hook up SST NGS to vehicle SELECT ITEM AND PR...

Page 730: ...EAS DIGITAL MEASUREMENTSYSTEM I II IllI GENERICOED II NNCTlONS SELECTITEMAND PRESSTRIGGERTO START PCM POWERTRAINCONTROLMODULE ABS ANTI LOCK BRAKEMODULE RAP REMOTEANTI THEFTMODULE DATA UNK DIAGNOSTICS...

Page 731: ...J2 59 1 I DTC P1838 continuous code Go to step 25 in Pinpoint Test B 1 J2 60 1 D TC PI846 PI867 self test 1 code Go to step 36 in PinpointTest B 1 DTC PI850 self test code Go to step 38 in Pinpoint Te...

Page 732: ...complete gear jumps out of gear travel 1 engagement Adjust shift lever rubber boot L Loose mounting bolts Tighten mountlng bolts pp Lubricate and repalr slip yokes as requ red dry or loose Tighten fl...

Page 733: ...e CW relay 1 Short to B J2 58 1 P I824 Electric shift relay ICircuit failure J2 58 1 1 PI826 1Electricshift relay 1Short to B 1 J2 58 1 1 PI828 1Transfer case relav rnoduleCCW relav 1 Circuit failure...

Page 734: ...Disconnect PCM BOB nstalled leave PCM d sconnected Does voltage fluctuate while measurlng read ngs I between test pins 14 and 24 at the BOB wh le o Go to next step cycl ng the 4x4L switch NOTE Transm...

Page 735: ...ohms Yes No Go to step 3 Repair circuit WILB foropen Reconnect and clear all DTCs and retest system I Reconnect GEM T 223 Connector Kev ON 1 Yes Service battery short reconnect switch Clear all DTCs a...

Page 736: ...ss connector Is battery voltage present 7 Key OFF D sconnect GEM T 223 connector Remove electrlc sh ft relay see pg J2 62 Check p n 15 GEM module Y wlre vehlcle harness connector for cont nulty to gro...

Page 737: ...DTCs and retest and F see pg j2 62 Is continuity present NO 1GO to step 20 19 Key OFF Remove fuse 27 D sconnect electrlc shlft control module Dlsconnectelectrlc shift relay see pg J2 62 D sconnect ba...

Page 738: ...eck circuit BR for cont nu ty to a round resent I ACTION Yes Repa r BRiP wlre circult for short to ground Clear all DTCs and retest No Replace all connectors and retest Yes GO to step 18 1 Yes 1 Go to...

Page 739: ...or pin 18for continuity to ground Is continuity present Replacetransfer case shift motor Reconnectall connectors Clear all DTCsand retest system Service circuit OM for short to ground Reconnect all co...

Page 740: ...t PUN for battery short If voltage does not exist replace transfer case shift motor p Check GEM refer to 97 B Series BETM Disconnect transfer case shift motor connector Recheck for voltage If voltage...

Page 741: ...14 connector Check for continuity between GEM connector T 223 connector pin 14 and instrumentcluster connector C 214 connector pin 14 circuit GY Is continuity present Yes Service circuit GY for open R...

Page 742: ...ector Check for continuity between GEM T 223 connector pin 10 and 1 instrument cluster C 214 connector pin 15 circuit LBIB Is continuity present 4 Instrument cluster C 214 connector d sconnected Key O...

Page 743: ...x 3 9kR 4x4 HIGH approx 1 lkQ 4x4 LOW approx 3600 3 If not as specified replace the 4x4 shift control switch MJ1166 A 5BUOJ2 047 Check shift motor 1 Disconnectthe electronicshift motor assembly Refert...

Page 744: ...Refer to page J2 35 ELECTRONIC SHIFT MOTOR ASSEMBLY Inspection Check shift motor sensors 1 Remove the electronic shift motor assembly Refer to page J2 35 2 Check for continuity between the shift moto...

Page 745: ...er to page J2 33 If continuity readings are inaccurate loosen switch screws and adjust switch position sensor until correct continuity readings are obtained in all corresponding transfer case position...

Page 746: ...H TCS MECHANICAL SYSTEM TEST K 90 TORQUE CONVERTER CLUTCH TEST K 90 LINE PRESSURETEST K 91 STALL TEST K 93 AIR PRESSURETEST K 96 TRANSMISSION K 98 TRANSMISSION UNlT REMOVAL K 98 TRANSMISSION UNlT DISA...

Page 747: ...K INDEX INDEX ATFTYPE MERCONmV CAPACITY 4x2 9 0 LITERS 9 5 US qt 7 8 Imp qt 4x4 9 3 LITERS 9 8 US qt 8 1 Imp qt I 4x4 MODELS 4x2 MODELS EXTENSION...

Page 748: ...h not shown Inspection page K 71 7 Selector lever Removal Inspection Installation page K 205 8 Solenoid valves Tester hook up procedure page K 75 Inspection In shop page K 76 Inspection On road page K...

Page 749: ...2 80 2 95 0 110 0 116 2 11 2 30 10 083 0 090 3 00 3 15 10 118 0 124 I Retaining ring to pressure plate clearance mrn in 1 3 2 0 0 051 0 079 1 Retaining ring Thickness mm in 1 37 0 0539 1 73 0 0681 2 0...

Page 750: ...learn the strategy CROSS SECTIONALVIEW I I MK1374 A 5BUOKX 004 1 Overdrive band 4R44Ei 4 Intermediateband 7 Rear one way clutch Front band 5R55E 5 Reverse and high band 4R44E 8 Forward clutch 2 Coasti...

Page 751: ...nspected quickly and easily The recommended troubleshooting sequence is described below 5BUOKX 259 Note For correct testing the engine speed should be checked with a tachometer For inspection of PCM t...

Page 752: ...m Normal Write R O Technician P R E C H E C K P R O C E D U R E S Review R O Review Repair History Check EngineElectrical System Performam Check For Non FactoryEquipment Check ShihLinkageAdjustment Ve...

Page 753: ...orange and switch overdrive off 2 Accelerate the vehicle with minimum throttle part throttle and wide open throttle 3 For 4R44E verify that 1 2 and 2 3 upshiftsand downshiftsare obtained For 5R55E ve...

Page 754: ...sareasshowninthevehiclespeedatshiftpoint table Refer to page K 9 6 Iftheshift pointsarewithinspecification the 1 2 2 3 3 4andtorqueconverterclutchshiftvalvesareOK 7 Shiftthe selector lever into N rang...

Page 755: ...8 1 2 20 27 I2 17 17 25 I0 16 2 3 33 41 20 263 29 40 I8 25 l 3 1 3 4 73 85 45 531 66 78 41 49 Part throttle 1 2 36 46 22 29 33 41 20 26 2 3 58 69 36 43 54 64 33 40 a 3 4 103 115 64 72 93 107 58 67 4 3...

Page 756: ...tle 20 35 12 22 17 25 10 1 6 t Minimum throttle 1 2 1 2 3 23 32 14 20 20 28 12 1 8 a 38 48 23 30 33 43 20 27 0 3 4 75 85 46 53 63 74 39 46 0 4 5 93 1 17 58 73 1 93 1 17 58 73 Axle ratio 3 08 kmh mph 2...

Page 757: ...therthanneutral Use the COOL 22 35 C 70 95 F range as a rough reference only HOT RANGE 5 Ensure that the ATF level is in the HOT 66 76 C 66 C TO 76 C I O O F TO 170 150 170 F range Add ATF to the spec...

Page 758: ...nnections 3 Oil cooler O RING PLUG LINE EPC PRESSURE 5R55E ONLY MK7061 B FRONT OIL PUMPSEAL TORQUE CONVERTER TO FRONT OIL I l3RNE PIATE STUDWELD PUMPGASKET I Check for fluid leaks around the converter...

Page 759: ...s of the transmission indicated in the Transmission Tester line of the QUlCK DIAGNOSIS CHART I can be easily checked by using the TransmissionTester 4 Input and output signals of the powertrain contro...

Page 760: ...QUICK DIAGNOSIS CHART K QUICK DIAGNOSIS CHART I Possible parts and referen Item Self diagnosis NGS Adjustment Breakoutbox Mechanicalsystem test Road test MK1144 F o...

Page 761: ...K QUICK DIAGNOSIS CHART QUICK DIAGNOSIS CHART 11 I Possibleparts and reference page Prelim inary 1 Emissioncontrol system 1 Elec tronic system On acceleration MK1146 E Check EPC see page K 78...

Page 762: ...QUICK DIAGNOSISCHART K...

Page 763: ...ration Surges while cruising Lack of power Poor iuel economy Vehicle does not move D 2 1 andlor R ranges Note 1 K 24 Excessive N to R range and N to range shift I shock felt 1 1 Frequent shifting 1 Do...

Page 764: ...elerator pedal released during cruisingat 1 mediumto high speed 28 Delayed shift I Vehicle shifts at high RPM I K 28 MK1151 E2 6BUOKX 266 1 1Transmission z n g e s noise 1 D 2 1 R ranges 27 Transmissi...

Page 765: ...lenoid valve connector disconnected Adjust idle speed Section FT I No Check solenoid valve wiring harness for open and or short circuits o If OK replace solenoid valve s o If not OK repair or replace...

Page 766: ...Is ATF level OK7 a page K 12 Level Between notcheson dipstick HOT RANGE 66 C TO 76 C l50 F TO 170 F COOL RANGE 22 C TO 35 C DO NOT VOoFTO 95 F DRIVEMARK ON DECELERATION 4 Yes No Is control pressure OK...

Page 767: ...rol pressure OK ACTION Go to next step page K 91 Yes I Go to next step Repair or replace parts as necessary Refer to PressureTest Diagnostic Chart on page K 92 Is torque converter clutch solenoid OK 1...

Page 768: ...peed sensor and wiring page K 68 Is control pressure OK page K 91 Repair or replace parts as necessary Refer to Control PressureTest Diagnostic Charts on page K 92 6BUOKX 272 Yes LACK OF POWER Perform...

Page 769: ...range Vehicle moves when accelerator pedal not depressed TROUBLESHOOTINGHINTS lnspect parts repair adjust or replace malfunctioning parts as necessary O Selector lever installation or adjustment inco...

Page 770: ...traincontrol module PCM malfunction s Section FT 8 Oil pump worn page K 123 O Powertrainworn reverseand high clutch overdrive band intermediateband andtor one way clutch page K 102 140 MKI 167 E 6BUOK...

Page 771: ...accelerator pedal depressed more than 718 t h i n kickdown range lnspect parts and wiring repair adjust or replace malfunctioning parts as necessary O ATF level low Q Selector lever installation or ad...

Page 772: ...nd 6 3 Oil pump worn WHEN UPSHIFTING AND OR DOWNSHIFTING Section FT page K 12 Section FT page K 146 page K 102 140 page K 123 I 24 NO ENGINE BRAKING I Eng ne speed drops to Idle but veh cle does not s...

Page 773: ...N I D 2 l R RANGES TROUBLESHOOTINGHINTS lnspect parts repalr adjust or replace malfunct on ng parts as necessary O ATF level low a j s page K 12 Q Idle speed low Section FT O Control valve body malfun...

Page 774: ...of the powertrain control system The Continuous Memory self test is always active The test consists of all the OBD II rnonitors and the comprehensive component monitor and is designed to detect failur...

Page 775: ...off 1 Insertthe vehicle interface module and program card into the SST NGS control unit 2 Plug in the NGS OBD II adapter into the interface module and the large 5 pin connector into the vehicle data l...

Page 776: ...to vehicle 2 Select vehicle and engine selection 3 Select vehicle year and model 4 Select diagnostic data link 5 Select PCM 2 6 Select diagnostic test mode 7 Select Key On Engine Off on demand self t...

Page 777: ...ey On Engine Running on demand self test 7 Start vehicle press start and trigger 8 Follow operating instructionsfrom the menu and perform BOO PSP and TCS cycling if equipped I DIAGNOSTIC TROUBLE CODE...

Page 778: ...T ITEM AND PRESSTRIGGER TO START I MF1692 B 7BUOKX 296 Output Control Test DIAGNOSTIC DATA LINK VlEW RECORDERAREAS DIGITALMEASUREMENT GENERIC OBD IIFUNCTIONS Note For 5R55E diagnosis and testing refer...

Page 779: ...F1692 B 7BUOKX 005 Accessing OBD II PID Mode Procedure CLEAR DIAGNOSIS CODES Note Start engineand bring upto operatingtemperature before running Quick Test After Repair Procedure 1 After repairshavebe...

Page 780: ...information and additional NGS diagnostic testing procedures 10 Presstrigger to capture data 11 Press trigger to save data 12 Select view reading 13 Press MAX 14 Press Graph Monitor graph for non lin...

Page 781: ...ission Solenoid malfunction Transmission Solenoid malfunction Transmission Solenoid malfunction Torque Converter Clutch TCC Condition Circuit low input Circuit high input Circuit low input Circuit hig...

Page 782: ...I I I 1 PI746 I Electronic PressureControl EPC Solenoid I Ooen circuit low inoutl I K 45 Sensor inconsistentwith MAF sensor Sensor out of Self Test range Circuit intermittent Circuit malfunctioning P...

Page 783: ...pry up on connector Depressrelease buttonthen pull up on connector Disconnect 16 pintransmission vehicle harness connector Using a mirror inspect both ends of connector for damaged or pushed out pins...

Page 784: ...inuity ACTION Go to step 6 Check for open or short in harness solenoid or PCM concern Replace PCM Go to step 14 Go to step 7 STEP 5 6 I No 1 ernal harness or solenoid concerns I Yes may cause readingo...

Page 785: ...h an ohmmeter For SSl test signal wire is gray and PWR wire is white For SS2 test signal wire is brown and PWR wire is white For SS3test signal wire is yellow and PWR wire is white Connectionshould sh...

Page 786: ...e transmissionupshift and downshift when commanded Removetransmission fluid pan Caution Use only MerconmV ATF or equivalent Use of any other fluids may result in a transmission malfunctionor failure V...

Page 787: ...solenoid DTCs first Go to step 4 Replace suspect solenoid and or body G G step 2 INSPECTION Yes No Check for DTCs retreived during self tests Are P1714 P1715 P1716 P1717 Pi740 still present If any of...

Page 788: ...r than 10 000 ohms Ensure transmission vehicle harness connector is disconnected Reconnect PCM Install line pressure gauge at line tap on case Installtransmission tester 49 UNOI 071 and 4R44E cable ov...

Page 789: ...etween BAT engine ground and appropriate wire Green lBlue with ohmmeter Connection should show inffnite resistance no continuity 1 Is there continuity Yes Go to step 9 1 No Servlce as requrred I I Yes...

Page 790: ...45 60 70 90 psi Go to step 4 Does pressure reading match the commanded pressure Removetransmission fluid pan Visually inspect all wires and connectors for damage Connect positive lead to VPWR solenoid...

Page 791: ...easure reslstance betweentest plns 71197 at BOB and the IVPWR p n at the transm ss on vehlcle harness connector Is each reslstance less than 5 ohms Ensure BOB IS installed 1Ensure transmlss on vehlcle...

Page 792: ...gative lead at black wire of TCC connector 1 Is resistance less than 0 5 ohms 1 Go to step 11 Replace internal harness Go to step 12 Check for continuity between BAT engine ground and I Yes Replace in...

Page 793: ...smission connector Is each resistance less than 5 ohms Key OFF BOB is installed Ensuretransmission vehicle harness connector and PCM are disconnected Measure resistance between test pln 28 and test pi...

Page 794: ...ep 12 Check for continuity between BAT engine ground and internal harness appropriate wire with an ohmmeter For CCS test signal wire is orange and VPWR wire is white Connection should show infinite re...

Page 795: ...734 PO784 Gear 4 PO735 Gear 5 P0736 PI701 Reverse MF70644 B 7BUOFl 074 TSS SENSOR MK7000 B FROM POWER RELAY TEST PIN 71 97 0 VPWR TEST PIN 53 0 SS3 TRANSMISSION TEST PIN 81 0 EPC HARNESS TEST PIN 27 S...

Page 796: ...oid 3 SS3 Sensor Signal Return TFT Coast Clutch Solenoid CCS 4R44E Shift Solenoid4 SS4 5R55E Shift Solenoid Power Electronic pressure Control EPC Power Electronic Pressure Control EPC Solenoid Not Use...

Page 797: ...6 1 1 2 1 2 2 Gear selector positioL OD 2 1 1 Gear selector position 1 2 3 4 I Gear selector position 553 always OFF L 2 2 r 1 OD 2 1 2 2 2 1 2 2 2 1 I SS3 always ON ECA gear commanded 1 2 I ECA gear...

Page 798: ...I Gear selector position 1 2 3 4 5 2 Ratio 1 1 2 3 Ratio 1 I 3 3 Flatio 1 I S S alwavs ON OD I 2 1 PCM gear commanded 1 2 3 4 5 Actual gear obtained 3 Ratio 1 1 3 3 Ratio 1 I 1 1 2 1 3 Ratio 1 1 1 2...

Page 799: ...with KOEO Yes ReplaceTCS verify complaint IS resolved If not go to next step 1 No Sewrce short crrcurt 1 Yes Concern may be rntermrttent Go to step 10 I No Go to next step Yes Reparr short to ground b...

Page 800: ...ON BOARD DIAGNOSIS SYSTEM K LED TEST PIN 0 TO KEYPOWER 79 TClL LOCATED IN INSTRUMENT CLUSTER TEST PIN 0 29 TCS LOCATED ON TRANSMISSION SHIFT LEVER...

Page 801: ...es stance between test plns 91 at BOB and approprrate s gnal prns at transmlss on connector Are both resrstancesless than 5 ohms 4 KeyOFF Ensure transrnlss on veh cle harness connector IS drsconnected...

Page 802: ...nuity between BAT engine 1 Yes Go to step 7 ground and appropriate jack TFT or TFT Connection should No 1 Service as required Replace internal harness show infinite resistance no continuity 1 No T e p...

Page 803: ...ansrnlsslon IS cold warm transmlsslonup If transmlss on IS warm allow transmlsslonto cool down Do TFT PlDs Increase as transmlsslon IS warmed up or decrease as transmlsslon IS cooled or do PlDs drop I...

Page 804: ...EST PIN 37 O Ei TFT SIG TEST PIN 91 GYIR SIG RTN TRANSMISSION HARNESS CONNECTOR Pin Wire I pin number color Circuit function I number color Circuitfunction TEST PINS LOCATEDON BREAKOUT BOX 1 Orange Sh...

Page 805: ...K ON BOARD DIAGNOSIS SYSTEM Transmission Fluid Temperature TFT Sensor...

Page 806: ...tatus lamp on tester cable match the selected gear positions tion before proceeding Apply parking brake Placetransmission in overdrive Verify shift linkage is adjusted in overdrive position Placetrans...

Page 807: ...nd test plns 3 49 and Go to step 9 50 at BOB Are all greater than 10 000ohms Drsconnect TR sensor Yes Concern IS not nthe TR sensor Install trans tester TR cable and cable overlay If dlagnos ng a star...

Page 808: ...CTOR VEHICLE HARNESS TR SENSOR PID CHART P p p p p Gear Position TR p p PIN 0000 W PK R W PWO YIB LBIB WIB P kt L Reverse REV Neutral 7 NTRL Dr ve O D Manual2 MAN2 1001 7 I Manual 1 p p p p MAN1 0011...

Page 809: ...stance betweentest pins 84 and test pins 91 71197 77 76 and 103 at BOB Is resistance greater than 10 000ohms Connect positive lead of voltmeter to TSS tester jack and negitivelead of voltmeter to TSS...

Page 810: ...Coast Clutch Solenold CCS 4R44E 10 Shlft Solenold Power Electron c Pressure Control EPC Power e n a Return T li Transm ss on Fluid Temperature TFT Electron c Pressure Control EPC Solenold Sensor Purpl...

Page 811: ...ATAMONITORAND RECORD I I Repair open or short in harness I decreases with engine and vehicle speed clear all DTCs and road test If concern is still present refer to Quick Diagnosis Chart in this secti...

Page 812: ...ANT TEMPERATURE SENSOR Inspection 1 Measure resistance of ECT sensor cold 2 Start engine and let warm for 5 minutes 3 Stop engine 4 Measure the resistance of the ECT sensor warm Specification Temperat...

Page 813: ...hicle speed sensor connector 2 Measure the resistance between the terminals of the vehicle speed sensor Resistance 190 250R 3 If not as specified replace the vehicle speed sensor Note An EPC solenoid...

Page 814: ...CTION MUST BE NEAR TOP SCREW AND WASHER 2 5 N m 25 kgf cm 22 in4bfl 7 Installa new driven gear on a new vehicle speed sensor 8 Secure the speedometer driven gear with the retainer 9 Install the new ve...

Page 815: ...tighten the bolts 5 Position the selector lever to N 6 Rotate the manual lever to the neutral position 7 Install SST 49 UN01 086 or equivalent to align the three slots in line on the TR sensor Note T...

Page 816: ...Y SELECT ITEM AND PRESS TRIGGER TO START 4 Select the PIDiDATA monitor and record function of the NGS 5 Select TPS on the NGS display Compare the TPS voltages to the following chart Specification Thro...

Page 817: ...re PID Voltages V 10 C 50 F 3 525 TURBINE SHAFT SPEED TSS SENSOR 20 C 68 F lnspection 1 Disconnectthe TSS sensor connector 2 Measurethe resistancebetweenthe terminals of the TSS sensor 3 095 30 C 86 F...

Page 818: ...o case and tighten attaching bolt Tightening torques 8 11 N m 82 112 kgf cm 61 87 inlbf 7 Reconnectvehicle harness OUTPUT SHAFT SPEED OSS SENSOR 5R55E ONLY lnspection 1 Disconnect the OSS sensor conne...

Page 819: ...X 038 Tester LED s and Controls 1 Overlay and cable correctly installed LED s only LED s with symbol and cable correctly match 2 Status LED s LED OFF when not activated by tester solenoid not activate...

Page 820: ...normal operatingtemperature 8 Perform On board Diagnostics 9 Record all DTCs 10 Service all non transmissioncodes 7BUOKX 041 Hook up Procedure Note During tester use additional DTCs may be set Theref...

Page 821: ...spection 1 Check EPC solenoid 1 Set ohmmeter to 100 200ohm range 2 Put switch in BENCH mode 3 Position Solenoid Check Dial in the OHMS CHECK position 4 Connect negative leadof ohmmeterto the EPCjack 5...

Page 822: ...0 ohm 1k scale 3 Connect positive lead of the ohmmeter to the TFT jack If Transmission is Warm 1 Set ohmmeter to 1K scale 2 Measure and record TFT sensor resistance between TFT jack and TFT jack 3 Let...

Page 823: ...itive lead to the appropriate sole noid VPWR jack 5 Check for voltage across each solenoid by activatingthe solenoid switches Select the appropriate solenoid with the rotary switch and depress the cor...

Page 824: ...performedon the hoist it may not be possibleto feel all shifts as they occur LEDs will turn GREEN when solenoids are activated LEDswillturn OFFwhensolenoidsaredeactivated Refer to the appropriate ove...

Page 825: ...activate 3 Does the transmission pass these tests If not perform Symptom Troubleshooting Refer to page K 18 6 Check turbine shaft speed sensor TSS Note This test may be performed on a hoist or on the...

Page 826: ...ssion Range TR Sensor Testing Using Tranmission Tester 4R44E and 5R55E Thetransmissiontester allowsatechnicianto operatethe electrical portion of the TR sensor 1 Perform Preparation and Hook upprocedu...

Page 827: ...onal circuit 1 Set test selector switch to the DIGITAL TR SENSOR TEST position 2 Press and HOLD each button while moving the gearshift lever through EACH gear position 3 Monitor each LED 4 The status...

Page 828: ...OSC control allows you to function the main components of the 5R55E quickly and easily and to provide accurate information to properly diagnose the transmission Performing Output State Control Enter O...

Page 829: ...trolthe EPC solenoidto obtaincommanded pressure 7BUOKX 954 SEND PlDS SSI SS2 SS3 SS4 and TCC in BENCH MODE These OSC functions are usedto turn solenoids OFFand ON when performing an electrical circuit...

Page 830: ...to 90 psi XXX cancels OSC for EPC I MK8957A Note If an OSC command is sent and the requirements are not met the PCM will abort the function and kick out of the OSC mode If vehicle requirements are not...

Page 831: ...after sending an OSC value the vehicle requirements are no longer met the PCMwill cancelthe OSC value and no error message will appear The OSC value XXX may be sent at any time to cancel the OSC It i...

Page 832: ...off when the vehicle is below 20 mph no excessive load on engine engine lugging 7BUOKX 959 EPC in DRIVE MODE This OSC function is used to increase the EPC pressure while testing the transmission gear...

Page 833: ...as sent by the OSC and the PCM has accepted the OSC substitution the PlDs function must be linked to the OSC function so that the parameters can be monitored To link the OSC and PID functions press th...

Page 834: ...he engine compartment 1 Disconnect the negative battery cable 2 Removethe speed control actuator if equipped 3 Disconnect the powertraincontrol module connector 4 Removethe two nuts and remove the pow...

Page 835: ...ometer and vacuum pressure gauge must be connected to the engine To check the torque converter clutch for engagementtdisengagement drive the vehicle at approxi mately 80 kmlh 50 mph and while maintain...

Page 836: ...WHEN 0 1 CONTAMINATED C CLEAN AND REPAIR TRANSMISSION FLUSH CONVERTER AND OIL COOLER t I ADJUST BAND S AS A MATTER OF NORMALMAINTENANCE BAND ADJUSTMENT IS NOT NECESSARY C rp LINE PRESSURETEST I 2 Chec...

Page 837: ...UNO1 071 MUST BE REMOVED and the vehicle wiring harness installed when performing this procedure Perform the line pressure test prior to performing the stall test DO NOT MAINTAIN WIDE OPEN THROTTLE W...

Page 838: ...rdriveservo Control valve bodv Forwardclutch Overdriveservo Control valve bodv I Low in manual 1st only I I Forward clutch Control valve body I Low in manual2nd only Intermediateservo 1 Overdrive serv...

Page 839: ...ise the ATF and engine coolant to operating temperature 4 Engage the parking brake and use wheel chocks at the front and rear of the wheels 5 Connect a tachometer to the engine Procedure 1 Start the e...

Page 840: ...n the same manner 1 0range 2 2 range 3 1 range Caution If the engine rprn exceeds the maximum rprn specified RELEASEthe accelerator pedal IMMEDIATELY Clutch or band slippage is indicated Engine stall...

Page 841: ...d reverse band and the one way clutch 4 R range malfunction of the reverse and high clutch or low and reverse band 5BUOKX 010 Preparation 1 Loosen the oil pan bolts and lower one edge to drain the ATF...

Page 842: ...iston has movedto the applied position 4BUOKX 027 Reverseand high clutch Apply air pressure to the reverse and high clutch A dull thud indicatesthat the reverse and high clutch piston has movedto the...

Page 843: ...speed ODs sensor 5R55E only 13 Disconnect the solenoid valve connector referring to Removal Note Refer to page K 100 14 Support the transmission on a jack 15 On 4x4 models disconnect the transfer cas...

Page 844: ...and 4 OL vehicles the torque converter nutsareaccessedthroughthestarter motormount ing opening Selector cable 1 Remove the selector cable from the manual shaft lever 2 Remove the nuts and bracket 3 Wi...

Page 845: ...d engine mounting member from the vehicle On 3 OL and 4 OL equipped vehicles remove the rear engine mount and engine mounting member as follows 1 Removethe rear engine mount bolts 2 On 4 OL equipped v...

Page 846: ...transmission mounting bolts 2 Slide the transmission toward the rear of the vehicle to disengage the pins and the torque converter 3 Lower the transmissionfrom the vehicle Warning Do not allow the tr...

Page 847: ...alike organize them so they do not get mixed up 6 Disassemblethe controlvalvebodyassemblyandthoroughly cleanitwhenaclutch or brakebandisburnt or when the ATF has degenerated 6BUOKX 395 Cleaning notes...

Page 848: ...TRANSMISSION K Components...

Page 849: ...n I Assembly page K 132 30 Thrust bearing No 3 31 Turbine Shaft Speed TSS sensor 32 Solenoid valve connector 33 Center support 34 lntermediate band anchor strut and adjusting screw 35 lntermediate ban...

Page 850: ...I A4FD HOLDING FIXTUREADAPTER T9 3T 77002 AH n I FIXTUREARM I PARK1 PAWL I PART OF BENCH MOUNTED HOLD1 FIXTURE T57TL 5 5 Remove the parking pawl spring and shaft 6 Mount the transmission to a workbenc...

Page 851: ...n so that any foreign materialwill remain in the oil pan 3 Install the assembly to the holding fixture as shown Caution Make sure the holdingfixture lock pin is secure 7 On 4 OLequippedvehicles remove...

Page 852: ...y check the transmission for the L I MK1315 A 5BUOKX 069 cause Caution Do notturnthetransmission over beforeremoving the oil pan so that any foreign materialwill remain in the oil pan Do not reuse the...

Page 853: ...ving the cover 2 Remove the reverse servo piston and spring 16 Remove the control valve body bolts Note Usea 10mm socket to removethe sixteenM6 x 40 mm four M6 x 45 mm and three M6 x 35 mm main contro...

Page 854: ...Use a small piece of cardboard or similar material to prevent tool from damaging passage INTERMEDIATE SERVO PISTON SPRING INTERMEDIATE SERVO AND SEAL ASSEMBLY INTERMEDIATE SERVO PISTON AND RODASSEMBL...

Page 855: ...Note Rotate and lift the converter housing so that the clutch assemblieswill stay in place 2 Remove the converter housing and oil pump assembly 3 Remove the gasket and thrust washer No 1 Compress the...

Page 856: ...31 Remove the overdrivelfront band actuating lever shaft Note Tag and identify the overdrivelfront leverfor assembly The overdrivelfront lever has a letter stamped into its side Note The overdrivelfro...

Page 857: ...ASE BRACKET OVERDRIVEIFRONT BAND LEVER I MK7106 B 7BUOKX 085 34 Remove No 2 needle bearing 35 Remove the overdrivelfront ring gear overdrivelfront one way clutch and the overdrivelfront center shaft a...

Page 858: ...ut is not ser viced separately Carefullydisconnecttheturbineshaftspeedsensor TSS connector from the 16 pincase connector Caution Do not pry on other wires or damagethe connector or case Carefully remo...

Page 859: ...Carefully push down on the top of the connector until it stops Depressthe tab and push down on the connector Removethe connectorand harnessthroughthe bottomof the case Caution Do not damage the conne...

Page 860: ...intermediateband adjusting screw 48 Remove the intermediate band Caution ldentify the band Note the position of the anchor side and apply side to refer to during assembly 49 Remove the intermediateba...

Page 861: ...clutch as sembly or the forward clutch assembly L NO 6A FORWARO RING GEAR HUB THRUST BEARING ASSEMBLY MK7915 A 7BUOKX 900 54 Remove the forward clutch assembly 55 Remove No 6A forward ring gear hub th...

Page 862: ...carrier hub assembly 60 Remove the input shell and forward sun gear 61 Remove No 8 thrust bearing Note Tag and identify No 8 thrust bearingfor assembly 62 Remove reverse planetaryring 4R44E or lowlrev...

Page 863: ...eve I I MK1352 A 1 66 Remove the snap ring Caution Do not reuse the snap ring Discard the snap ring and replace it during assembly Removing the snap ring releases the output shaft Hold the output shaf...

Page 864: ...Remove the low and reverse band Caution Identify the band Note the position of the anchor side andthe applysideto referto duringassembly 71 Remove the output shaft Caution The output shaft is model de...

Page 865: ...75 Remove the inner manual valve lever and park rod Note Removing the snap ring releases the output shaft Hold the output shaft when removing the snap ring 76 Useasmall hammer and drift to lightlytap...

Page 866: ...ace is not removable TORQUE CONVERTER Preparation SST I I I 49 0378 400A checking 4BUOKX 119 The torque converter is welded together and cannot be disassembled 4BUOKX 120 Inspection 1 Check the outer...

Page 867: ...050 in Stator to impeller interference check 1 Positionthe oil pump on the torque converter and engage the front oil pumpsplines to the torque converter one way clutch inner race I I MK1367 A 5BUOKX...

Page 868: ...ce as necessary 3 Assemble in the reverse order of disassembly referringto Assembly Note 49 UNOl 015 Pump alignment tool set 1 Oil pump 4 Front pump thrust washer No 1 2 Oil pump seal 5 Torque convert...

Page 869: ...BUOKX 912 4 Remove the screws from the oil pump with Tore 40 wrench L I MK7114 B 7BUOKX 911 Caution Discard the screws They are not reusable for as sembly I PUMP SUPPORT SEAL RING 5 Remove the oil pum...

Page 870: ...1 Install new front oil pump seal onto SST 49 UN01 153 Note Checkand makesurethat the garter spring hasnot poppedoff of the converterhub to converterhous ing seal Caution Place the converter housing...

Page 871: ...formed for transmission assembly 1 Inspectthe fluid pump to converter housing bushingand front oil pump seal Replace converter housing assem bly if necessary Note Fluid pump to converter housing bushi...

Page 872: ...correct arbor from the SST that will be the tightest fit when placed over the pump support Caution The SST must be used to properly align the pump to the converter housing in order to prevent seal le...

Page 873: ...rect snap ring when assembling MK1011 A 4BUOKX 135 Disassembly InspectionIAssembly 1 Disassemble in the order shown in the figure referring to Disassembly Note 2 Inspect all parts and repair or replac...

Page 874: ...dediameter of the drumwhile blockingthe other hole with a finger OUTER SEAL INNERSEAL II OUTER II SEAL INNER SEAL PISTON Warning Do not exceed 137 kPa 20 psi Wear safety glasses when using compressed...

Page 875: ...and clear of debris 7 lnspect the clutch plates for wear scoring and fit on the clutch hub serrations Replaceall platesthat are badly scored worn or do not fit freely in the hub serrations 8 lnspect...

Page 876: ...p If reusing plates grooves must be installed clockwise I D to O D L I MK7119 B Coasting clutch clearance 1 3 2 0mm 0 051 4 079 in SNAP RING RETAINING PLATE COASTING CLUTCH DRiJM I I MK1011 A Snap rin...

Page 877: ...4E or Front 5R55E center shaft 3 Overdrive 4R44E or Front 5R55E one way clutch 4 Overdrive 4R44E or Front 5R55E ring gear RETAINING OVERDRIVE RING GEAR OVERDRIVE CENTER SHAFT 5 Overdrive 4R44E or Fron...

Page 878: ...and center shaft assembly Check for cracks i n the roller cage and wear on the roller clutch Inspect the press fit of the one way roller clutch to the center shaft 4 Temporarily insert the planetary g...

Page 879: ...ed surface areas where the rollers contact the races lnspect the needle bearing on the nose of the planetary gear overdrive carrier 4 Remove and inspect the No 2 planetary thrust bearing 5 Remove coas...

Page 880: ...ligned with the needl b aring inside the planetary gear carrier The sun g ar will not seat properly if the No 12sun gearthrust bear ing raceis not alignedinthe center of the sun gear 10 Install the co...

Page 881: ...l plates 11 Inner seal ring 5 Snap ring 12 Forward clutch drum DisassemblyNote page K 136 13 Seal rings 6 Retainer 14 No 5 forward clutch cylinder thrust bearing Disassembly note Snap ring 1 Installth...

Page 882: ...WARD PISTON Assembly procedure Forwardclutch 1 Installthe forward piston 1 Apply ATF to the new inner and outer seals and install them on the piston 2 Installthe rubber cushion spring Caution If there...

Page 883: ...ch plates in alternating order starting with a steel plate Caution When installingnew friction plates the word TOP should face up If reusing plates grooves must be installed counterclockwise Note If n...

Page 884: ...ce 1 4 2 1 mm 0 05 5 0 083 in Snap ring sizes Forward clutch 0 0681 125 1 4 925 0 0819 125 1 p p 4 925 2 44 0 0961 125 1 4 925 11 Install the center support or Thrust Washer Select Tool D86L 700014 A...

Page 885: ...riction and steel plates 7 Reverse and high piston Inspect for wear or burning 8 Outer seal ring 4 Snap ring 9 Inner seal ring Disassembly Note age K 140 10 Reverse and high clutch drum For disassembl...

Page 886: ...ess the direct clutch piston into SST Caution Lubricate the inner and outer direct clutch piston seals with MerconOV transmission fluid 3 lnspect drum band surface bushing and thrust sur faces for sco...

Page 887: ...ce being careful not to darn age the seal rings Caution Care must be taken to prevent rollover of the seal lip I I MK1044 A 2 Installthe springsand spring retainer intothe reverseand high clutch drum...

Page 888: ...ng a screwdriver 10 Measure the reverse and high clutch clc larance 1 Push down on the drive plates and measure the clearance betweenthe retaining plate and snap ring 2 If the clearance is not within...

Page 889: ...sembly IAssembly 1 Disassemble in the order shown in the figure referring to Disassembly Note 2 Assemble in the reverse order of disassembly referring to Assembly Note For removal of oil seal MK1049 A...

Page 890: ...O CLOCK EXTENSION HOUSING SEAL REPLACER T74P 77052 A A s s e m b l y note Bushing Install the bushing using Extension Housing Bushing Replacer T77L 7697 F or equivalent Note Inspect counterbore of ext...

Page 891: ...and passages with compressed air Wear eye protection when using compressed air to clean components Each valve should slide outtin under its own weight When a valve will not slide out under its own wei...

Page 892: ...TRANSMISSION K...

Page 893: ...lenoid 39 TCC valve 40 TCC spring 41 Retainer 42 Plug 43 TCC valve solenoid regulator valve 44 TCC spring 2 3L 1 spring 3 0L 4 OL 2 springs 45 Retainer 46 Plug 47 Coasting clutch valve 48 Coasting clu...

Page 894: ...solenoids are not interchangeable Note If the TCC valve backs out install using the TCC solenoid 3 lnstall the solenoid retainer 4 lnstall SS1 and SS3 Caution The solenoid terminals must face upward...

Page 895: ...nd spring are not inter changeable with the EPC limit relief valve and spring L I MK1394 A 9 Install the EPC limit relief valve and spring Caution The converter relief valve and spring are not inter c...

Page 896: ...der shown in the figure referringto Assembly Note I MK1391 A 1 Main control valve body 2 Gasket 6BUOKX 141 3 Separator plate Assembly Note page K 151 Assembly note Separator plate 1 Installand alignth...

Page 897: ...et Note Apply petroleum jelly to hold the gasket in place CONTROL VALVE BODY ON VEHICLE REMOVAL INSTALLATION On Vehicle Removal Caution Clean the transmission exterior thoroughly with a steamcleaner o...

Page 898: ...ins from the solenoidbrackets 7 Removethe detent spring I I MK1537 A 5BUOKX 145 8 Removethe reverse servo 1 Removethe reverse servo piston cover and gasket SOLENOID CONNECTOR r Warning The piston asse...

Page 899: ...control valve body screws 9 Remove the control valve body screws 10 Remove the control valve body as an assembly On vehicle installation 1 Install the alignment pins into the case in the positions sho...

Page 900: ...KX 152 5 Installthevalve bodyboltsinthepositionsshowninthe figure I M6 X 45MM 4 REQUIRED I M6 X 35MM 2 REQUIRED I I M6 X 30MM 2 REQUIRED I 20 MM 4REQUIRED SERVO COVER 6 Tighten the valve body boltsint...

Page 901: ...NECTOR I I I Note The wiring guide snaps into placeon the solenoid retainers 9 lnstallthe wiring loom protector and guide Align the pins in the holes of the solenoid brackets and gently push down Caut...

Page 902: ...recaution 1 Ifthedriveplates overdriveband intermediatebandor lowandreversebandarereplacedwith newones soak the new parts in ATF for at least thirty minutes before installation 2 Before assembly apply...

Page 903: ...SMISSION Bearing washer and bushing locations 4R44E and 5R55E BEARING SLEEVE SEAL BEARING RACE SELECTIVE WASHER I NEEDLE BEARING I SELECTIVE NEEDLE BEARING THRUST WASHER m BUSHING m WASHER I MK1409 C...

Page 904: ...TRANSMISSION K Components...

Page 905: ...nput shell and forward sun gear 48 Extension housing 19 Intermediate apply lever and shaft 49 Transmission case 20 Intermediate band apply strut 50 Input shaft 21 lntermediate anchor strut and adjusti...

Page 906: ...Install the retaining pin 4 lnstall the inner manual valve lever and parking pawl actuating rod into the case Align the flats of the inner manual valve lever with the flats on the manual lever shaft...

Page 907: ...reverse drum clockwise to install Caution Thetabs onthrustwasher shouldface the one way clutch Note Use petroleum jelly to hold the thrust bearing in place MK1414 C 5BUOKX 169 NO 10 6 Install the thr...

Page 908: ...TRANSMISSION K 1 7 Installthe output shaft OUTPUT SHAFT 8 Installthe output shaft ring gear...

Page 909: ...1353 C 5BUOKX 173 10 Install the output shaft sleeve with the cone facing up I I MK1548 A 7BUOKX 174 REVERSE CARRIER NO 9 NEEDLE 0 NEEDLE BEARING 11 Install the low reverse carrier assembly 1 Install...

Page 910: ...8 REVERSE CARRIER 3 Place the assembly into the transaxle Caution Make sure the thrust washers stay in place Note Use petroleum jelly to hold the thrust washers in I place I MK7132 B 7BUOKX 176 4 Inst...

Page 911: ...old the low and reverse band in place INPUT SHELL I I MK1181 A 5BUOKX 179 N0 5 NEEDLE BEARING REVERSEAND HIGH CLUTCH FORWARD CLUTCH ASSEMBLY 13 Install the forward gear assembly 1 Installthe needle be...

Page 912: ...ar and hub in the forward clutch assembly as shown Caution Make sure the thrust washer No 6 and thrust bearing No 6 remain in place 6 Installthethrustbearing No 7 intheforwardringgear as shown Note Bl...

Page 913: ...te If sun gear snap rings or input shell require service perform steps a through e a Remove rear snap ring and sun gear from input shell b Remove front snap ring from sun gear c Install new front snap...

Page 914: ...Add readingA and reading B together Divide by two Subtractthe thickness of GaugeBar1 93T 77003 AH or equivalent 17 78mm 0 700in This is readingC 7 Refer to reading C and select the thrust bearing No 4...

Page 915: ...intermediate band apply shaft through the intermediateservo lever Note The intermediatebandapply shaft isshorter than the overdrive 4R44E or front 5R55E band apply shaft I I MK1551 A 7BUOKX 193 I 18...

Page 916: ...diate band adjusting screw as a temporary guide Note The intermediate band and overdrive 4R44E l front 5R55E anchor struts are identical 21 Installthe thrust bearing No 4 selected instep 14on the cent...

Page 917: ...the nut and cage assembly is in place Note Make sure the cage and nut is properly tightened If not tightened properly a late shift condition may develop MK7135 B 5BUOKX 417 1 1 25 Installthe center su...

Page 918: ...the wiring I I MK1558 A 5BUOKX 418 27 lnstall the Turbine Shaft Speed TSS sensor on the center support Tightening Torque 8 1 1 N m 82 1 11 kgf cm 71 97 in lbf MK1436 A 7BUOKX 201 28 lnstall the thrust...

Page 919: ...gear carrier and exciter wheel MUST be replaced Note PerformTSS air gap clearance check A MK1560 A 7BUOKX 419 33 Placethethick bladeof SSTover theturbineshaft speed TSS sensor as shown Rotate the exc...

Page 920: ...ting clutch drum assembly COASTING CLUTCH DRUM 36 Install the bracket and the band apply lever 37 Installthe band apply shaft Caution The overdrive 4R44E lfront 5R5 iE band apply shaft is longer than...

Page 921: ...1562 B 7BUOKX 207 39 Installthe band over the coasting clutch drum Note If the band is reused it must be installed in the same position as when removed MK1328 A 7BUOKX 208 1 40 Install the band anchor...

Page 922: ...e sure the oil pump is seated against the thrust washer and the clutch drum assembly The oil pump body must be belowthe level of the case gasket surface 3 PlaceGaugeBarT93T 77003 AH orequivalentacross...

Page 923: ...071 Green 1 85 1 90 0 073 0 075 Red 1 95 2 00 i 0 077 0 079 Be ge 2 0 5 2 1 0 0 081 0 083 Black 2 1 5 2 2 0 0 085 0 087 Yellow 43 Remove the oil pump 44 Install the appropriate thrust washer No 1 that...

Page 924: ...e dimple on the larger gear must be down when in the pump housing gear pocket I I MK1004 A 7BUOKX 423 52 Place the separator plate on top of the oil pump Caution Do not allow the pump gears to come ou...

Page 925: ...ST over the pump support unt l it bottoms in the pump gear pocket MK1009 A 5BUOKX 428 2 1 57 Tighten the Allen head screws Tightening torque 22 28 N m 2 2 2 9 kgf m 16 21 ft lbf 58 Remove the SST I I...

Page 926: ...the converter housing and front pump support and gear assembly Install the SST or equivalent Note The splines on the input shaft are not the Sam length The shorter splines go intab the assembly MKI56...

Page 927: ...ilthere isagap between the servo cover and the snap ring 6 Carefully install the servo cover snap ring 7 Carefully back off the nut on the SST until the servo spring is unloaded Caution The servo cove...

Page 928: ...tall but do not tighten a new locknut on the adjusting screw 2 Backoff theadjustingscrewexactly twoturns andhold in that position 3 Tighten the locknut Tightening torque 48 61 N m 4 9 6 2 kgfsm 354 5f...

Page 929: ...71 lnstall a new valve body gasket Note Use petroleumjelly to hold the gasket in place Make sure the holes in the gasket line up with the holes in the control valve body 72 lnstall the SST or equivale...

Page 930: ...ts inthe sequenceshown in the figure Tightening torque 8 1 1 N m 82 1 12 kgf cm 71 97 in lbf 75 Remove the pin near the manual valve and install the detent spring Tighteningtorque 8 1 1 Nm 82 1 12 kgf...

Page 931: ...7 Loosen the adjusting screw until the p ston pad bot toms out on the tool Recordthe distance traveled X Specification 3 0 5 6 mm 0 120 4 220 in 54153 2 11212 085 1 Groove 51150 2 01411 986 No Groove...

Page 932: ...res to the solenoids and irkstallwire loom protector and guide 81 Perform Inspection In shop Refer to page K 62 I MK1408 A 1 82 Install new O rings on the oil strainer 83 Apply MerconaV ATF or equival...

Page 933: ...ion housing Note Use petroleum jelly to hold the gasket in place 90 lnstall the extension housing Refer to page K 144 91 lnstall the two studs and the four bolts Tightening torque 37 51 N m 3 8 5 2 kg...

Page 934: ...m 30 410ft lbf 97 Align transmission heat shield retaining clips over fluid pan rail and install heat shield on the fluid pan rail 5R55E only 98 Install trarlsmission heat shield nut Tighten heat shie...

Page 935: ...erter using Torque Converter Handles T81P 7902 C or equivalent Note TORQUE CONVERTER Lightly lubricatethe converter hubwith MerconBV ATF or equivalent Warning The torque converter can fall out if the...

Page 936: ...Section J 8 lnstall the rear engine mount and engine mounting member referring to lnstallation Note 9 Remove the jack 10 Connect the Transmission Range TR sensor connector referring to lnstallation No...

Page 937: ...TRANSMISSION POWER FLUSHING Note After servicing oil pump torque converter control valve body servo piston end band brake band or transmission removal and replacement the trans mission cooler must bef...

Page 938: ...llthe hanger onto the rear engine mount 4 Remove the rear engine mount bolts Tightening torque 82 108 N m 8 3 1 1 0 kgf m 60 80 ftalbf 1 I MK1064 8 5BUOKX 249 Transmission Range TR sensor Connect the...

Page 939: ...e On 2 3L and4 OL models thetorqueconverter nuts are accessed through the starter motor opening 4BUOKX 268 Torque converter undercover Install the torque converter undercover Tightening torque 17 21 N...

Page 940: ...A 6BUOKX 253 1 Oil cooler Removal Note page K 195 Removal note Oil cooler 1 Raise and support the hood 2 Remove the oil cooler bolt upper 3 Raise the vehicle on a vehicle hoist 4 Place a suitable cont...

Page 941: ...5 Attach a hose to the outlet oil cooler pipe and install the free end of the hose into the funnel 6 With the transmission in N Neutral run the vehicle at 1000 rpm 7 Watch the fluid flow for a solid...

Page 942: ...PES REMOVAL1 INSPECTION1 INSTALLATION 1 Remove bracket bolt 2 Remove all clips 3 Loosen the oil cooler pipe fittings 4 Removethe oil cooler pipe 5 Inspect all parts and replace as necessary 6 Install...

Page 943: ...ecessary 4 Install in the reverse order of removal referring to Installation Note 1 Drive plate mounting bolts Installation Note page K 198 2 Drive plate I InstallationNote Drive plate mounting bolts...

Page 944: ...itch I Damaaed shift lock actuator Shift Control Linkage Binding Damaged shift cable and Go to PinpointTest B 1 K 203 out of proper gear relationship bracket Loose shlft cable and bracket Loose retain...

Page 945: ...rommet Install new transmission Excessive shift effort n transmission ket loose 1bent p Transmission Range Selector Transmission shift cable Reinstall transmission shift Lever will not shift from rang...

Page 946: ...B wire between the sh ft lock actuator connector and ground Is reslstance less than 5 ohms7 D sconnect sh ft lock actuator connector Remove blown fuse NO Servlce GYN wire for open Retest system No Ser...

Page 947: ...emove in the order shown in the figure referring to Removal Note 3 Inspect all of the parts and repair or replace as necessary 4 Install in the reverse order of removal 5 After installation check the...

Page 948: ...he locktab on the top side of the selector cable by pushingdown onthe two tangs and unlock the adjuster body 6 Make sure the selector cable moves freely by moving the selector cable back and forth the...

Page 949: ...sary 4 Install in the reverse order of removal referring to lnstallation Note Removal note Selector lever 1 Depressthetwo lockingtabs onthe selector lever pivotpin retaining clip 2 Remove the selector...

Page 950: ...d but will not produce any particular symptom If the circuit is shorted the EEC PWR fuse 30A will burn out 5BUOKX 308 Ground If there is a poor ground the engine may not start Malfunction lndicator La...

Page 951: ...ensor circuit or PCM is shorted or grounded PO705 is output If the TR sensor circuit is above maximum voltage PO708 is output 7BUOKX 315 Evaporative Emission EVAP Canister Purge Solenoid If the evapor...

Page 952: ...ue converter lockup will occur If TCC slippage is detected PO741 or PO744 is output If TCC solenoid circuit fails during on board diagnosis PO743 is output If TCC malfunction is detected P I740 is out...

Page 953: ...ture sensor NA PI 117 output PI 117 output PCM 91 Engine coolant NA temperature sensor MF1123 C 5BUOKX 327 PCM 85 lgnlt on control module Brake On 1Off BOO Switch Code No PO340 output Code No PO340 ou...

Page 954: ...r relay Transmlsslon fluld temperature sensor sensor I PCM power relay Turbine shaft soeedsensor MF1743 C Shift Solenoid 1 SS1 MF1741 B 1 5BUOKX 331 A Short circuit Poor ground No PO712 PO713 Circuit...

Page 955: ...ay ODs sensor ElectricalPressure Control EPC Solenoid Short circuit Code No P1717 P0735 PO765 Improper gear selection Mechanicalfailure Condition Circuit PCM 6 PCM power relay OSS sensor 1 Condition C...

Page 956: ...noid Code No PI754 output No engine break ng NA I PCM 28 Coast ng clutch solenold PCM power relay Coastlng clutch solenold PCM power relay Torque converter clutch solenoid MK1488 A 7BUOKX 137 Code No...

Page 957: ...PROPELLER SHAFT TROUBLESHOOTING GUIDE L 2 PROPELLER SHAFT L 2 REMOVAL INSTALLATION L 2 INSPECTION L 3 OVERHAUL L 4 ADJUSTMENT L 13 5BUOl X 005...

Page 958: ...bolts attaching the rear propeller shaft to the rear axle 3 On 4x4 models remove the bolts attaching the rear propeller shaft to the transfer case 4 Remove the rear propeller shaft referring to Remova...

Page 959: ...Remove the plug from the extension housing and inspect the housing seal for damage Replace 1 heseal if neces sary 3 Slide the center yoke into the transmission extension housing making sure the marks...

Page 960: ...d install the front propeller shaft to the transfer case Tightening torque 17 22 N m 1 7 2 2 kgf m 13 16 ft4bf OVERHAUL Caution Universaljoint components from different manufacturers and new and used...

Page 961: ...PROPELLER SHAFT L 4x4 REAR LWB I WB REAR CAB PLUS...

Page 962: ...n page L 9 11 Front propeller shaft Inspection page L 9 12 Half roundyoke Assembly Note page L 9 13 Center bearing support Disassembly Note page L 9 Assembly Note page L 9 14 Bushing lnspect for harde...

Page 963: ...ol 180 to pressonthe spider and remove the remaining bearing cup from the opposite side T74P 46354 Spider Remove the spider after the bearing cups have been removed 4BUOLX 019 ML1025 A 5 For front pro...

Page 964: ...1030 A 6BUOLX 004 U JOINT TOOL Slip yoke dust boot 1 Removethe slip yoke from the splined stub shaft after the boot clamps have been removed with end cutter pliers Center yoke Warning Use gloves or a...

Page 965: ...oration and replace if necessary 413UOLX 023 Inspection Front propeller shaft rear propeller shaft 1 Measure the front and rear propeller shaft runout with a dial indicator 2 Replacethe front and or r...

Page 966: ...L r SMALL DIAMETER 6 Push the slip yoke onto the stub shaft making sure the blind splines are aligned 2 On 4x4 models install the small diameter side first pushing the boot as far as it will travel o...

Page 967: ...the snap ring 8 Apply pressure on the centering sockel yoke and install the remaining bearing cup 6BUOLX 005 Bearing cup spider Note The spider bosses or lubrication plugs on kits must be assembled i...

Page 968: ...e sure the U joints are free to rotate easily without binding before installing the propeller shaft Replace the U joints if necessary I ML1036 A 10 If binding has resulted from misalignment during the...

Page 969: ...the ride height X between the top of the axle tube andthe bottomof the frame rail The vehicle mustbe inthe curbweight unloaded condition Findthe recorded ride heigh tinthe DrivelineAngle chart in Sect...

Page 970: ...e Check the propeller shaft and pinion angles with the engine angle within specification ML1044 A FRAME I5 1 1 COMPONENT ANGLE ML1048 A YOKE EAR I T 2 T a 2 i k7 ML1049 A Note The protractor cannot be...

Page 971: ...d reinstall in vehicle 4 If the vibration persists disconnect the propeller shaft at the rear yoke 5 Rotate the rear yoke 180 degrees and reconnect the propeller shaft to the rear yoke 8 Check the axl...

Page 972: ...ed of this vibration period as a baseline speed 4 Runthe vehicle until the propeller shaft rotating speed is 64 80 km h 40 50 mph Note Do not run the vehicle for an extended period of time 5 Carefully...

Page 973: ...y 45 degrees away from each other and test for correction of vibration 9 If necessary continue to rotate the clamps apart in smaller increments until the vibration becomes re duced or eliminated 10 If...

Page 974: ...EMBLY ASSEMBLY M 19 FRONT AXLE CASING 4x4 M 20 REMOVAL INSTALLATION M 20 REAR AXLE M 23 PREPARATION M 23 ON VEHICLE MAINTENANCE M 23 REMOVAL INSTALLATION M 26 REAR AXLE CASING M 29 REMOVAL 1 INSTALLAT...

Page 975: ...axle casing 4x4 Removal lnstallation 5 Rear axle Removal lnstallation page M 6 page M 7 page M 9 page M 11 page M 14 page M 19 page M 20 page M 26 6 Rear axle casing Removal lnstallation 7 Front diff...

Page 976: ...scoslty Above 18 C O F C Below 18 C O F1 I SAE 90 SAE 80W I Capac ty hters US pt Imp pt I 1 42 3 2 5j 7 7 6 5 j 3 5 3 0 3 1 MM1166 C 4BUOMX 190 REAR AXLE Rear axle 1 Axle casing 1 Integraltype Axle sh...

Page 977: ...14 Damaged or broken boot I Replace M 14 Faulty boot clamp I Replace M 14 Possible Cause lnsufflc ent front d fferent al 011 Incorrect front d fferent al or1 lmproperly adjusted backlash of rlng gear...

Page 978: ...ing 1 M 64 Worn or damaged ring gear Worn or damaged rear bearing Replace Worn or damaged pinion and side gear 1 Replace Seizure of side gear and case Replace Worn spline of side gear Replace Worn pin...

Page 979: ...4 Remove and discard the cotter pin ADJUSTING NUT 5 Remove the retainer 6 Loosen the adjusting nut three turns 7 Grasp and rock the wheel and tire assembly Note Tap on the caliper with a plastic hamm...

Page 980: ...sary Refer to page M 6 17 Pump the brake pedal KNUCKLE Removal Ilnstallation 1 Jack up the vehicle and support it with safety stands 2 Remove the wheel and tire assembly 3 Remove the caliper disc plat...

Page 981: ...ent 6 Strike the lower arm as shown in the figure to remove the knuckle Caution Donot usea balljoint separatorfork to separatethe knucklefrom the lower arm Installation note Knuckle 1 Install the knuc...

Page 982: ...le bearing playwith the hands held at the top and bottom of the tire Wheel bearing play 0 00 0 08mm 0 000 0 003 in 2 Inspect the wheel for smooth rotation Note any rough feeling or abnormal noise from...

Page 983: ...Tightening torque 1 8 N m 18 3 kgfzm 16 in lbf I 1 12 Install the washer k I Note Tighten the inner locknut slightly to align the lock nut pin with the washer hole 13 Tighten the outer locknut using t...

Page 984: ...o page M 14 6 Remove the tie rod nut referringto Removal Note Refer to page M 12 7 Remove in the order shown in the figure referringto Removal Note 8 Inspect all of the parts and repair or replace as...

Page 985: ...ter 1 Mark the position of the camberlcaster adjuster 2 Remove the camberlcaster adjuster using Pitman Arm Puller T64P 3590 F or equivalent 4BUOMX 019 Lower ball joint 1 Remove the snap ring 2 Assembl...

Page 986: ...e hole in the lower ball joint 3 lnstall a new cotter pin 4 lnstall the snap ring on the upper ball joint stud 5 lnstall and tighten the upper ball joint pinch bolt Tightening torque 88 1 15 N m 9 0 1...

Page 987: ...P 5 Remove the hub assembly Refer to page M 89 for manual locking wheel hubs and page M 86 for automatic locking wheel hubs 6 Remove in the order shown in the figure referring to Removal Note 7 Inspec...

Page 988: ...amps Removal Note InstallationNote 11 Front axle drive shaft Disassembly l Assembly page M 18 12 Rubber boot Removal Note page M 16 InstallationNote page M 18 13 Oil seal Removal Note page M 18 Instal...

Page 989: ...spindle with a plastic hammer to remove it from the knuckle 4BUOMX 031 Clamps If removingthe right front drive axle shaft mark the yoke and front drive axle shaft prior to separation BUOMX 032 Rubber...

Page 990: ...Cleanalldirt andgreasefromthe bearingbore The bearing bore must be free from nicks and burrs Oil seal lnstall the oil seal using the SSTs Note Apply high temperature grease to the oil seal Rubber boot...

Page 991: ...Cup Replacer T73T 42224 or equivalent Note SST number 49 F027 003 Driver Handle 4BUOMX 043 Outer bearingcup Install the outer bearing cup using the SST and Bearing Cup Replacer T73T 4222 B or equivale...

Page 992: ...bly Note below 5 Stub shaft Assembly Note below Disassembly Note Bearing cups Press out the bearing cups using U Joint Tool T74P 4635 C or equivalent If the bearing cannot be pressed all the way out o...

Page 993: ...rt it with safety stands 2 Disconnect the front propeller shaft Refer to Section L 3 Removethe wheel and tire assembly 4 Removethe caliper Refer to Section P 5 Remove in the order shown in the figure...

Page 994: ...X 011 Spring 1 Compress the spring usingajack and liftingthe front axle casing 2 Remove the nut 3 Slowlylowerthejackand frontaxlecasingandremovethe spring spacer seat and stud Note Support the front a...

Page 995: ...Support the front axle casing at all times during installation Do not allow the lower arm to hang from the brake hose Tightening torque 95 1 35 N m 9 7 1 3 8 kgf m 70 1 00 ftelbf 6BUOMX 013 Shock abso...

Page 996: ...ing removal of bearing and seal OIL SUPPLY PORT 1 ON VEHICLE MAINTENANCE Rear DifferentialOil Inspection 1 Remove the oil supply port plug MM1028 A 2 The oil levelshouldbethe specifieddistancebelowthe...

Page 997: ...he SST Note SST numbers 49 F027 003 Driver Handle 49 H025 001 Axle Tube Bearing Replacer 8 Installthe rear axle Refer to page M 26 Wheel Bearing Play Inspection 1 Jack up the rear of the vehicle and s...

Page 998: ...ft 9 On differentials equipped with a 3 73 l or a 4 10 1 ratio axle pushthe pinion shaft until it alignswith the lockbolt hole 10 Install the lockbolt Tightening torque 21 40 N m 2 1 4 1 kgf m 15 30 f...

Page 999: ...PLASTIC COVER BOLTS 21 27 2 1 2 7 15 20 I 7 5 INCH AXLE ASSEMBLY SHOWN 8 8 INCH AXLE ASSEMBLY SIMILAR MM1037 C 1 Brake drum 2 Differential cover Removal Note below Installation Note page M 28 3 Lockb...

Page 1000: ...X 016 Installation Note Rear axle 1 Carefully install the rear axle 2 Slide the splines into the side gear Caution Do not damage the rear axle splines oil seal or bearing during installation Note On d...

Page 1001: ...rential cover and axle casing 2 Apply abeadof sealant3 18 4 76mm 0 1 2 M 1 8 7 5 in wide to the differentialcoveras shown inthe figure 3 Install the differential cover within 15 minutes of applying se...

Page 1002: ...wn in the figure referring to Removal Note 5 Install in the reverse order of removal referring to lnstallation Note I MM1039 B 1 Brake lines and parking brake cable Removal Section P 2 Vent hose Remov...

Page 1003: ...ent hose from the vent Rear axle casing 1 Support the rear axle casing using a transmission jack 2 Remove the brake line from the clip I I MM1042 A 3 Remove the brake line iunction block 4 Remove the...

Page 1004: ...the vehicle 2 Install the U bolts and nuts 3 Tighten the nuts Tightening torque 88 108 N m 9 0 1 1 0 kgf m 65 80 ftelbf 4 Install the brake line into the clip 5 Screw the vent hose into the vent 4BUOM...

Page 1005: ...0 N m 1 4 2 7 kgf m 10 1 5 ftdbf Steps After Installation 1 Install the wheel and tire assemblies Tighteningtorque 115 1 55 N m 15 3 1 5 8 kgf m 85 1 15 ft lbf 2 Fill the differential with the specifi...

Page 1006: ...dle bearings For inspection of differential gear assembly For removal of needle bearing For removal of differential gear assembly 49 F027 003 Driver handle For removal of inner and outer bearing race...

Page 1007: ...NANCE Front DifferentialOil Inspection 1 Remove the oil supply port plug Note Place the vehicle on a flat level surface I I MM1177 A 1 2 The oil level should be the specified distance below the oil su...

Page 1008: ...spring does not pop out of the seal Replacethe seal if the spring pops out 10 Install the dust shield onto the companion flange as follows 1 On Dana 35 axles install the companion flange usingCompanio...

Page 1009: ...ront axle drive shafts Refer to page M 14 6 Remove in the order shown in the figure referring to Removal Note DANA 35 I MM1045 8 1 Differentialgear assembly Removal Note page M 37 Disassembly page M 3...

Page 1010: ...2 Cleanand inspect the internalworking partsfor wear and damage 3 Rotatethe gears checkingfor any roughnessor grinding 4 Check the ring gear teeth for scoring abnormal wear nicks or chips SCORED MM104...

Page 1011: ...308 Impact Slide Hammer 2 On Dana35axles removethe oil seal usingthe SSTsand Seal Puller TOOL 1175 AC or equivalent Left oil seal Remove the oil seal using the SSTs and Axle Bearing Puller T90T 1225 A...

Page 1012: ...ssembly Note 8 Oil slinger 9 Front bearing 10 Collapsible spacer 11 Bearing inner race Disassembly Note 12 Oil baffle page M 40 Disassembly Note 13 Bearing outer race page M 40 Disassembly Note 14 Sid...

Page 1013: ...3 Differential gear assembly 1 Remove the differential gear assembly MM1056 B 5BUOMX 026 Caution Do not damage the machined surfaces Bearing caps Make a note of the matching letters on the bearing cap...

Page 1014: ...rive pinion oil slinger selective shim and inner bearing using a plastic hammer Warning Use care when handling the drive pinion as the gear teeth may be sharp Caution Catch the drive pinion to prevent...

Page 1015: ...e tools from the rear of the differential casing as shown in the figure BUOMX 021 Side bearing 1 Remove the side bearings using a press and Bearing Pulling Attachment D84L 1123 A or equivalent 2 Match...

Page 1016: ...damage the oil slingerlselective shim while removingthe rear bearing 4BUOMX 106 1 INSPECTION Inspectfor the following problems and replace any faulty arts 1 Poor meshing wear and damage of the ring ge...

Page 1017: ...referring to Total DifferentialGear Assembly End Play Refer to page M 45 2 Measurethe selectiveshimthickness referringto OilSlingeriSelectiveShimThicknessCheck Refer to page M 46 3 Assemble in the or...

Page 1018: ...20 Bearing cup 21 Differentialcasing Assembly Note page M 50 22 Bearing cap Assembly Note page M 51 page M 51 page M 51 page M 52 page M 52 page M 52 page M 53 page M 54 page M 55 DUMMY BEARINGS 8 6 4...

Page 1019: ...oil baffle in the bearing inner race bore of the differential casing Old Pinion 8 5 3 0 J 10 8 lo 08 5 08 05 I0 08 05 03 0 08 05 1 03 0 t 5 05 0 1 03 05 New Pinion Marking English 7 Old Pinion Markin...

Page 1020: ...g Cup Replacer T71P 4616 A or equivalents 4 lnstall the SST 49 8531 568 and O ring to the SST 498531565 and installthem intothe differentialcasing 5 Installthe SST 49 8531 567 yoke and washer 6 Tighte...

Page 1021: ...ctive shim which will bring the reading within specification Note Ifthe drive pinion is markedwith a plus reading this amount must besubtracted fromthe thickness dimension If the drive pinion is marke...

Page 1022: ...bearing by tightening the handle T76P 4020 All Tightening torque 1 7 3 9 N m I7 4 40 4 kgf cm 15 35 in Ibf rrrl cn 11 I C GAUGETUBE GAUGE BLOCK T76P 4020 A10 10 Insert the thickest feeler gauge possib...

Page 1023: ...a press the SST and Pinion Bearing Replacer T57L 4621 9 or equivalent Collapsiblespacer Caution Never reuse a collapsible spacer It must be replacedwhen it is removed 4BUOMX 115 Oil seal 1 Apply gear...

Page 1024: ...acer must be replaced 5 If rotational torque is not within specification tighten the locknut until it is within specification Caution Never tighten the locknut more than 474 N m 48 3 kgf m 350ft lbf o...

Page 1025: ...r 6 Repeat this procedure until the same reading is obtained Record the measurement B 7 Subtract measurement B above from measurement A Total differential gear assembly end play refer to page 1 0 6 9...

Page 1026: ...l the side bearings using a press the SSTs and Differential Side Bearing Replacer T85M 4221 A or equivalent 3 Install the required amount of shims and the side bearings onto the ring gear side I I MM1...

Page 1027: ...s 1 Installthe side bearings using the SSTs 2 Install the side bearings on the ring gear side using the SSTs Differentialcasing 1 Installthe SST 2 Attach dial indicator to the SST 3 Spread the differe...

Page 1028: ...tening torques Dana 28 41 6 1 N m 4 2 6 2 kgf m 30 45 ft Ibf Dana 35 64 91 N m 6 5 9 2 kgf m 47 67 ft Ibf 2 Checkthe ringgear and pinionbacklash atthree spots on the ring gear Standard backlash 0 13 0...

Page 1029: ...d check the tooth contact 3 Ifthetooth contact iscorrect wipe off the coating of red lead 4 If it is not correct adjust the pinion height and then the backlash I I MM1080 A 5 Toe and flank contact I T...

Page 1030: ...ote below InstallationNote page M 58 2 Left oil seal 6 Left front axle casing InstallationNote page M 58 7 Differentialgear assembly 3 Right oil seal InstallationNote page M 58 Installation Note page...

Page 1031: ...d Axle Seal Replacer T87P 3254 A or equivalent Snap ring Install the snap ring using a screwdriver Caution Do not tap on the center of the snap ring it may damage the snap ring Differentialgear assemb...

Page 1032: ...ghtening torque 102 1 28 N m110 4 13 1 kgfam 75 95 ftslbf 4BUOMX 129 Steps After Installation 1 Installthe front axle drive shafts Refer to page M 14 2 Installthe knuckles Refer to page M 11 3 Install...

Page 1033: ...49 UN27 004 Collar B For selection of oil slingerl selective shim 49 0727 570 Pinion height gauge body For installation of rear bearing Driver handle For installation of races 49 UNOl 034 Shim driver...

Page 1034: ...k and record ring gear runout referringto Ring Gear Runout Test Refer to page M 62 5 Check and record ring gear backlash referringto Ring Gear Backlash Check Refer to page M 62 6 Remove in the order s...

Page 1035: ...exceeds the maximum check for improper torque of the ring gear bolts or dirt betweenthe ring gear and the case 5 If after checkingfor impropertorqueor dirt the runoutstill exceeds the maximum the caus...

Page 1036: ...earingcaps must be installed1intheir original positions U I WM1127 A Differential Gear Assembly 1 Pry the differential gear assembly bearing cups and shims out until they are loose in the bearing caps...

Page 1037: ...cer Disassembly Note page M 65 13 Drive pinion 4 Pinion shaft Disassembly Note page M 67 Disassembly Note page M 65 14 Rear bearing 5 Pinion gears and thrust washers Disassembly Note page M 67 Disasse...

Page 1038: ...T70P 4221 A OR T57L 4220 A Remover T70P 4221 A or T57L 42204 or equivalents I I MM1133 A 4BUOMX 139 Pinion shaft pinion gears and thrust washers side gears and thrust washers Note On differentials equ...

Page 1039: ...he drive pinion Recordthe rotational torque to be used during assembly 2 Mark the companionflange in relationto the drive pinion 3 Holdthe companion flange with the SST and remove the locknut Companio...

Page 1040: ...bearing and remove it through the rear of the axle casing 4BUOMX 144 Rear bearing Remove the rear bearing using Pinior Bearing Cone Remover T71P 4621 B or equivalent CONE REMOVER T71P 4621 B I MM1138...

Page 1041: ...e pinion Assembly Note page M 71 10 Companion flange Assembly Note page M 71 11 Locknut Assembly Note 12 Side gears and thrust washers Assembly Note 13 Pinion gears and thrust washers Assembly Note 14...

Page 1042: ...the nut on the SST 49 8531 565 making sure the yoke can still be turned by hand 5 Install the SSTs 49 UN27 001 and 002 onto the SST 49 8531 565 6 Place the SST on a surface plate and set the dial indi...

Page 1043: ...thick ness Rear bearing 1 Place the selected oil slingerlselective shim on the drive pinion 2 Press on the rear bearing using the SST Note The samerearbearing usedinthis proceduremust be used in fina...

Page 1044: ...f lubricant to the drive pinion splines 2 Align the mark on the companion flange with the markon the drive pinion Note If a new companion flange is beirig installed dis regard the scribe mark on the d...

Page 1045: ...er no circumstances should the locknut be backedoff to reduce rotationaltorque If rotational torque reduction is required a new collapsible spacer and locknut must be installed Pinion gears thrust was...

Page 1046: ...on the speed sensor ring must be aligned with the slot in the gear case as shown 2 Startthetwo ringgear boltsthroughthe gear case intothe ring gear to make sure case to ringgear bolt hole align ment i...

Page 1047: ...MBLY SIMILAR I MMl161 C BUOMX 160 1 Bearing cup 6 Brake drum 2 Differential gear assembly 7 Differential cover Installation Note below Installation Note page M 28 3 Shim 8 Lockbolt 4 Bearing cap 5 Rea...

Page 1048: ...5 Rotatethe differentialgear assembly to ensurefree rota tion MM1156 A 1 6 Check the ring gear and pinion backlash 0 5rnm 0 020 IN 0 5rnrn 0 020 IN Backlash Preferred 0 30 0 38mm 0 0124 015 in Standar...

Page 1049: ...quired 1 mm in I 0 228 0 009 0 254 0 010 0 219 0 011 0 304 0 012 0 330 0 013 0 355 0 014 Thickness I change required mm in 0 304 0 012 0 355 O 6 41 r 0355 0014 1 1 0 406 0 016 I 0457 0018 1 045710 018...

Page 1050: ...015 in OIL SUPPLY PORT Specification 6 35 14 28mm 0 25 4 56 in 20 lnstall the oil supply port plug o r52mm 0 006 0 152mm o 006 IN Tightening torque 21 41 N m 2 1 4 1 kgfam 15 30 ft lbf 16 Remove the b...

Page 1051: ...rings referring to Disassembly Note Refer to page M 79 3 Disassemble in the order shown in the figure referring to Disassembly Note 4 Clean and inspect all parts and replace as necessary 1 Lockbolt 5...

Page 1052: ...g Differential Side Bearing Remover T70P 4221 A or equivalent I MMI097 A 4BUOMX 164 Lockbolt and pinion shaft The lockbolt and pinion shaft will have been removed during the rear axle procedure 4BUOMX...

Page 1053: ...gears and clutch packswith the shims Note Thesidegearsandclutchpacksfromthe individual sides should be kept together to be installed into their original sides during assembly 6BUOMX 032 Inspection Cle...

Page 1054: ...bolt 3 Side gears 9 Gear case Assembly Note page M 83 Assembly Note page M 84 4 Thrust washer 5 Pinion gear Assembly Note page M 83 Assembly Note Clutch pack 1 Assemble the clutch packs without the sh...

Page 1055: ...ce the base portion of Traction Lok ClutchGaugeT84P 4946 A orequivalentinavise Install the clutch pack and side gear without the differential clutch pack shim over the base of the gauge 4 Install the...

Page 1056: ...essof the new shim Be sure to lubricate the friction plates with an appropriate friction modifier prior to assembly 8 Assemblethesidegear theclutchpackandthe newshim 9 Repeat steps 1 through 8 for bot...

Page 1057: ...akaway torque may fluctuate with new clutch plates 9 Remove the lockbolt and the pinion shaft Note The pinion shaft and the lockbolt will be installed during the rear axle drive shaft installation Gea...

Page 1058: ...0 5 in of the threadedarea use as is If they are not coated apply sealant to the threads 2 Positionthe ring gear andthe speed sensor ring if the speed sensor ring was removed on the gear case Align t...

Page 1059: ...rt it with vehicle stands 2 Remove the wheel and tire assemblies 3 Remove in the order shown in the figure referring to Removal Note 4 Install in the reverse order of removal referringto lnstallation...

Page 1060: ...on using the SST Note SST number 49 UNOI 037 Hex Locknut Wrench Tightening torque 47 N m 4 8 kgf m 35 ft lbf MMlO91 A 4BU0MX 178 3 Spin the disc plate and loosen the adjusting nut one quarter turn 90...

Page 1061: ...he knuckle key slot 4BUOMX I79 nbly I I cam assembly Cam assen Inrtqll thc I I MM1092 A 4EiUOMX 180 LEGS 1 CAM KEY Align the cam key on the cam assembly with the knuckle key slot Caution Useextremecar...

Page 1062: ...the reverse order of removal referringto lnstallation Note I MM1094 C 1 Retainer 2 Manual locking hub assembly 3 Axle shaft spacers Removal Note InstallationNote 4 Outer locknut Removal Note lnstallat...

Page 1063: ...the disc plate counterclockwise while tightening the inner locknut to specification using the SST Note SST number 49 UNO1 042 Hub Locknut Wrench Tightening torque 47 N m 4 8 kgf m 35 ft lbf 3 Spin the...

Page 1064: ...hten the outer locknut with the SST Tightening torque 203 N m 20 7 kgfem 150 ft lbf 2 Check the wheel bearing play Wheel bearing play 0 004 08mm 0 00 0 003 in I MMIOIO B BUOMX 18 3 Attach a pull scale...

Page 1065: ...HOOTINGGUIDE N 5 STEERING WHEEL AND COLUMN N 6 STEERING GEAR N 23 STEERING LINKAGE N 31 POWER STEERING N 35 PREPARATION N 35 TROUBLESHOOTINGGUIDE N 35 AIR BLEEDING N 36 POWER STEERING FLUID N 37 STEER...

Page 1066: ...INDEX INDEX...

Page 1067: ...ssembly Assembly 2 Manual steering gear Removal lnstallation Disassembly Inspection Assembly 3 Power steering gear Removal lnstallation Disassembly Assembly page N 6 page N 39 page N 8 page N 12 page...

Page 1068: ...002 Power 2 3L I3 OL 4 0L A P 4 Rearc ball Tors on bar 17 I ATF Type F M2C33 F or DEXRON5II Model Item Steerlng wheel Loc oc Steerlng gear Gear ratlo O lllubr cant TYpe Manual 6 1 Rec rc ball worm 23...

Page 1069: ...bsorber Loose shock absorber mounting bolts Stuck or damaged ball joint Damagedor worn front wheel bearing lmproperly adjusted front wheel alignment Worn steering gear Worn or damaged ball joint Loose...

Page 1070: ...6 Measurethe preloadrequiredto rotatethe steering wheel at a constant speed for approximately 1 112 turns 7 Ifthe preloadis notwithin specifications readjust preload Specifications 0 224 68 N m 2 6 i...

Page 1071: ...bf 6 Tightenor loosenthe adjuster nutuntilthe correct preload is obtained 7 Tighten the adjuster locknut Tightening torque 225 253 N m 22 9 25 8 kgf m 166 1 87 ft lbf 8 Rotatethe wormshaft from stopto...

Page 1072: ...k vehicle with the wheels straight ahead 2 Disconnect battery negative and positive cables Wait one minute before proceeding with removal 3 Remove in the order shown in the figure referring to Removal...

Page 1073: ...emoval Note Steering column opening cover steering column cover reinforcementand steering column center reinforcement 1 Removetwo screwsand pull cover straightout to release clips 2 Removesix screws a...

Page 1074: ...ainer and removeshift cable from bend bracket 3 Remove steering column from vehicle Installation Note Transmission Shift Cable 1 Push shift cable retainer into slot on bend bracket and snap shift cabl...

Page 1075: ...40 54 P1 m 4 2 5 4 kgf m 30 40ftelbf 5BUONX 043 7 Transmission control shift indicator MN1177 A 6BUONX 004 Steering Column Opening Cover Reinforcement P R N 2 1 Tightening Torque 11 13 N m 1 I 1 38 k...

Page 1076: ...column in a soft jawed vise 2 Disassemble in the order shown in the figure referring to Disassembly Note 3 Removethe foam weather seal from the column tube referring to Disassembly Note 4 Assemble in...

Page 1077: ...r tube Assembly Note page N 22 14 Steering column lock actuator lever pin Disassembly Note page N 17 15 Column lock shifter pawl Assembly Note page N 20 16 Plastic bearing retainer 17 Steering column...

Page 1078: ...lock cylinder to RUN 2 Using flat tipped punch push on button below lock cylinder 1 MN1182 A 1 3 Pull out lock cylinder Air bag sliding contact Caution Be sure air bag sliding contact internal lock is...

Page 1079: ...t by pushing snap back at 6 00 position then 3 00 position then 12 OO position and remove from steering shaft I I MNI 184 A 5BUONX 049 Turn indicator cancel cam Removecancelcamby pushingupwithflat bla...

Page 1080: ...Remove three screws attaching shift interlock solenoid and shift selector position insert MN1187 A 2 Remove shift interlock solenoid and shift selector position insert together If necessary remove pu...

Page 1081: ...uator lever piri Pry on end of lever pinthat is stickingout and removewith Vise grips MNI 190 A Lock cylinder housing Caution Steeringcolumn positionspring will release when bolts are removed Remove t...

Page 1082: ...5 Inspection Check all bearings for damage or excessive wear If bearings are damaged replace accordingto procedures outlined in this section 5BUONX 056 Assembly Note Lock actuators 1 With actuator hou...

Page 1083: ...eenlockleveranclactuator housing to hold up lock lever Slowly loosenand remove C clamp 3 Position steeringcolumn lock spring and left column lock lever Using 6 inch 150mm C clamp compress spring while...

Page 1084: ...m 13 2 7 kgf m 14 1 9 ft4bf 5 Remove nuts from underneath right and left lock levers 6 Slowly loosen and remove C clamp I J MN1200 A 5BUONX 078 Fixed Steering 1 Positionlockcylinderhousing on upper lo...

Page 1085: ...w snap ring using a W4 inch ID by 2 1 R inch long PVC pipe 5BUONX 062 lgnition switch Note Ignition switch should be in RUN position Align pin from ignition switch with slot in lock column assembly Po...

Page 1086: ...o Double D slot of bearing then turn counterclockwise90 degrees 1 I MN1206 A 5BUONX 065 Transmission column shift selector tube Installtube and coat bushing with grease Tightening torque 7 1 1 N m 0 7...

Page 1087: ...ingshieldfromthesteeringgear inputshaftshieldandslideitupthe intermediate shaft 2 Remove the bolt and steering gear input shaft shield 3 Remove in the order shown in the figure referring to Removal No...

Page 1088: ...ring gear input shaft bolt Tightening torque 40 3 54 7 N m 4 1 5 5 kgf m 29 4 39 9 ft lbf 6BUONX 007 Pitman arm 1 Alignthe two blockedteeth onthe pitman armwiththe four missing teeth on the sector sha...

Page 1089: ...nspection page N 27 10 Wormshaft lnspection page N 27 Assembly Note page N 29 N m kgfm ft4bf 1 5BUONX 071 11 Wormshaft upper thrust bearing 12 Wormshaft lower bearing cup Disassembly Note page N 26 As...

Page 1090: ...a unit 9 MN1003 A 4BUONX 094 PULLER T58L 101 B Wormshaft lower bearing cup Remove the wormshaft lower bearing cup using Puller T58L 101 B or equivalent AN1004 6 4BUONX 095 Wormshaft upper bearing cup...

Page 1091: ...ace 4BUONX I00 Sector shaft 1 Inspectthe sectorgear teethfor chipping excessivewear and surface breakdown Replacethe sector shaft if dam age is found 2 Measure the clearance between the sector adjusti...

Page 1092: ...Cup Replacer T82T 3504 AH or equivalent BEARINGCUP REPLACER T82T 3504 AH Sector shaft seal Install the sector shaft seal using Bearing Cup Replacer T82T 3504 AH or equivalent I BEARING CUP REPLACER T...

Page 1093: ...heck the clearance between the screw head and the bottom of the sector shaft T slot Clearance Maximum 0 1Omm 0 004 in 3 If the clearance is greater than the specification install a new shim as require...

Page 1094: ...erclockwise 10 Installthe sector cover washer and bolts Note Donottorquetheboltsunlessthereislashbetween the sector shaft and wormshaft Lash can be ob tained by turning the screw counterclockwise Tigh...

Page 1095: ...lnstallation Note 4 Check the vehicle toe in and adjust if necessary Refer to Section R 0 VlEW W SPINDLE TN SERVICE M CO TTER PIN REPLACE I VlEW W MNI054 0 1 Center link 3 Outer tie rod Removal Note p...

Page 1096: ...link 1 Removethecotterpinand nutfromthecenterlinkballstud at the pitman arm 2 Place the jaws of Pitman Arm Puller T64P 3590 F or equivalentbetweenthe pitmanarmandthe center linkball stud boot 3 Tighte...

Page 1097: ...man Arm Puller T64P 3590 F or equivalent betweenthe spindle and the outer tie rodboot 3 Tighten the adjusting screw until the outer tie rod sepa rates from the spindle 4 Loosen the bolts on the adjust...

Page 1098: ...it 2 Positionthe adjusting sleeve clamps facing down Tighteningtorque 40 57 N m 4 1 5 8 kgf m 3 0 4 2 ft lbf 3 Position the inner tie rod in the center link Tighteningtorque 70 1 00 N m 7 2 1 0 0 kgf...

Page 1099: ...wheel runout Loose lug nut s Unbalancedwheel s Cracked or worn engine mount rubber Cracked or worn transmission mount rubber Cracked or worn steering gear mount rubber Loose steering gear mounting bol...

Page 1100: ...lcking steering column bearing N 8 N 39 Abnormal noise from N 49 steering system Loose steering gear mounting bolts T ghten N 40 Caution Be careful to avoid prolonged cranking as the battery may be dr...

Page 1101: ...ce and apply vacuum Vacuum 68 85 kPa 20 25 in Hg 7 Cycle steering wheel from lock to lock every 30 seconds for approximately 5 minutes Caution Do not hold steering wheel on stops 8 Shut engine off rel...

Page 1102: ...essure generated by the oil pump If the pressure is not within specification replace the oil pump assembly Refer to page N 69 Oil pump fluid pressure 2 3L 4 0L 7240 8480 kPa 73 8436 5 kgf cm2 1050 1 2...

Page 1103: ...n the torque at 45 from the stop Meshload checking and setting I Vehicles With 0 43046 km 0 5000 Miles CHECKING Reset if total meshload over rr echanical center is less than 1 13 N m l0 in lbf greater...

Page 1104: ...Bleed the air from the power steering gear Refer to page N 36 N m kgf m ft lbf MN1209 A 5BUONX 028 1 Steering gear shaft U joint upper shield 4 Steering gear 2 Flex coupling Installation Note page N...

Page 1105: ...f necessary Handleall parts carefully to avoid nicks burrs scratches and dirt Do not use solvent on seals 1 Rotatethe input shaft from stop to stop counting the total numberof turns Then turn the inpu...

Page 1106: ...ONX 031 6 Worm bearing race locknut Disassembly Note page N 43 7 Worm and valve assembly Disassembly Note page N 43 Assembly Note page N 43 8 Piston Assembly Note page N 45 Disassembly Note Valve hous...

Page 1107: ...small pocket knife under them and cutting thern off Caution Do not scratch the valve sleeve 6BUONX 011 Assembly Note Worm and valve sleeve assembly 1 Mount the worm end of the worm and valve sleeve as...

Page 1108: ...d onto the valve sleeve seals Allow the sizing tool to sit over the seals for five minutes Caution Do not bend the seals over while using the sizing tool 7 Verify that the seals turn freely in the gro...

Page 1109: ...nggear housing Turn the input shaft to center the piston 3 Apply petroleum jelly or equivalent to the sector shaft journal and positionthe sector shaft and cover assembly in the gear housing 6BUONX 01...

Page 1110: ...reseal and dust seal with NLGI No 2 2 Apply NLGI No 2 to the sector shaft seal bore 3 Place the dust seal on Sector Seal Replacer T77L 3576 A or equivalentwith the raisedlipof the seal toward the tool...

Page 1111: ...unt of NLGl No 2 betweenthe two seals 1 Dust seal Disassembly Note Assembly Note 2 Snap ring Assembly Note 3 Oil seal Disassembly Note Assembly Note SEAL REPLACE 4 Bearing page N 48 Disassembly Note p...

Page 1112: ...ls 4BUONX 149 MN1020 B 4BUONX 148 Inlet outlet tubes Remove the inlet and outlet tubes using Tube Seat Remover T74P 3504 L or equivalent 4BUONX 150 Assembly Note Inlet outlet tubes 1 Coat the fluid in...

Page 1113: ...l pump 2 Loosen the belt tension and remove the drive belt from the pulley referring to Removal Note 3 If necessary remove the oil dipstick tube 4 Remove in the order shown in the figure referring to...

Page 1114: ...N POWER STEERING I I MN1029 D 5BUONX 076 1 Oil pump pulley 2 Oil pump Removal Note N 52 Installation Note page N 52 InstallationNote N 53 Disassembly Assembly page N 54...

Page 1115: ...Note page N 52 Disassembly Assembly page N 54 Installation Note page N 53 1 2 3L AND 4 OL DRIVE BELT INSTALLATION 1 GENERATOR IDLER TENSIONER IDLER W P CRANKSHAFT Removal Note Drive belt 1 Onthe 2 3La...

Page 1116: ...172 B 4BUONX 159 Oil pump pulley I Install Pulley Removal Tool T69L 10300 Bor equivalent on the pulley 2 While holdingthe Pulley RemovalTool nutstationarywith a wrench rotate the inner spindle of the...

Page 1117: ...f m 35 4 7 ft Ibf Oil pump pulley Install the pulley using Pulley Replacer Tool T65P 3A733 C or equivalent Note Make sure the pull off groove on the pulley is facing the front and is flush with the en...

Page 1118: ...R STEERING Disassembly1 Assembly 1 Disassemble in the order shown in the figure referring to Disassembly Note 2 Assemble in the reverse order of disassembly referring to Assembly Note O RING n E P l n...

Page 1119: ...60 Assembly Note 17 Shaft seal page N 59 Disassembly Note Assembly Note page N 59 18 Retainer Disassembly Note Assembly Note page N 57 19 O ring page N 59 page N 59 page N 56 page N 57 page N 56 page...

Page 1120: ...retaining ring While applying pressure to the retaining ring place a screwdriver under the edge of the ring and remove the ring MN1036 A 4BUONX 164 Lower plate disc spring 1 Place the pump housing on...

Page 1121: ...er 1 InstallanewrotorshaftsealusingSeal DriverT78P 3733 A3 or equivalent and plastic mallet 2 Install the retainer using Seal Driver T78P 3733 A3 or equivalent and a plastic mallet Disc spring The dis...

Page 1122: ...SEAL DRIVER T78P 3733 A3 5 Place Seal Driver T78P 3733 A3 or equivalent into the rotor shaft hole 6 Press on the lower plate lightly to seat the O rings...

Page 1123: ...avities have been filled PLACE DOWEL PINS THROUGH THESE HOLES INLET PORTS Note Be careful when turning the rotor that the springs and slippers already installed do mot fall out Upper plate When instal...

Page 1124: ...over fits directly over the recess in the upper plate MN1048 A 4BUONX 174 Retaining ring 1 Place the pump assembly in C clamp T74P 3044 A1 or equivalent and compress the valve cover in the pump housin...

Page 1125: ...ulleys I I MN1142 A 4BUONX 177 Drive belt tension check All three engines are equippedwith automatic tensioners that indicate when the drive belt is worn A pointer and BELT gauge are built into the te...

Page 1126: ...ER PIS 4 TENSIONER CRANKSHAFT A C PS GENERATOR AIR CONDITIONING 1 I D LESSNC WATER I PUMP Replacement 1 On the 2 3L and 4 OL engines loosen the drive belt tension by liftingthe tensioner pulley in the...

Page 1127: ...FRONT PARKING BRAI ECABLE P 37 REAR PARKING BRAKE CABLE P 37 PARKING BRAKE PEDAL P 38 REAR ANTI LOCK BRAKE SYSTEM RABS P 38 DESCRIPTION P 38 TROUBLESHOOTING GUIDE P 38 WIRING DIAGRAM P 39 RELATIONSHI...

Page 1128: ...P INDEX INDEX BRAKE SYSTEM...

Page 1129: ...assembly Assembly page P 12 page P 13 page P 13 page P 14 page P 15 page P 16 page P 17 page P 19 page P 20 page P 21 page P 22 6 Front brake disc lnspection On vehicle Removal Inspection1 lnstallatio...

Page 1130: ...age P 37 Removal Inspection Releasing cable tension page P 35 Installation page P 37 Resettingcable tension page P 36 4 Parking brake pedal Resetting pedal control Removal Inspection1 spring tension p...

Page 1131: ...INDEX REAR ANTI LOCK BRAKE SYSTEM C3 FRONTOF VEHICLE FRONTOF VEHICLE VIEW A VIEW B...

Page 1132: ...ensor rotor RABS and ABS 2 RABS control unit Removal I Inspection Removal1 Installation page P 65 Installation page P 66 3 Rear speed sensor RABS and ABS 5 RABS hydraulic unit Removal Installation pag...

Page 1133: ...INDEX 4 WHEEL ANTI LOCK BRAKE SYSTEM...

Page 1134: ...mm n 3 0 0 12 brake mm n 20 6 0 811 Disc plate runout 0 008 0 003 I n I Type i Leading trailing L nlng mln th ckness Worn to wlthln 0 794 0 03 of any rivet head Rear drum Drum lnner dlameter Std d am...

Page 1135: ...heel bearing preload lmproper adjustment of wheel alignment Unequaltire air pressure No brake pedal play lmproper adjustment of push rod clearance Clogged master cylinder return port Disc pad or brake...

Page 1136: ...re enter the master cylinder 4 Repeat this procedure until air ceases to escape at the fittings MP1100 A 1 FRONTOF h 5 Placea box wrenchonthe bleederfitting on the RearAnti Lock Brake System hydrauli...

Page 1137: ...the brake master cylinder and HCU dis connect the 40 pin plug from the Control Unit and install the SSTs to the wire harness 40 pin plug 10 Place the other end of the vinyl tube in a clear container 1...

Page 1138: ...or flare nut s if necessary 4BUOPX 009 Flexible hose Checkfor scars cracks and swelling of the flexible hose Replace the hose if necessary Note A wet appearanceon the outer cover of the flexible hose...

Page 1139: ...fluid onto painted surfaces If spilled wipe it off immediately 1 Remove the brake fluid from the reservoir by using a suction pump 2 Fill the reservoir with clear1brake fluid 3 Attach a vinyl tube to...

Page 1140: ...all replace the check valve MP1126 A 5BUOPX 011 BRAKE PEDAL Inspection On vehicle The brakesystem isdesignedto permita full strokeof the master cylinder when the brake pedal is fully depressed Brake p...

Page 1141: ...of removal referringto lnstallationNote 4 Check the unit for correct operation ESS 1 WP1002 B 1 Stoplight switch harness connector not shown 2 Spring retainer 3 Spacer 4 Stoplight switch 5 Brake pedal...

Page 1142: ...n CLUTCH MASTER CYLINDER PUSH ROD NOTSHOWN 0STOPLIGHTSWITCH HARNESS CONNECTOR NOT SHOWN I MP1003 C 1 Stoplight switch harness connector not shown 2 Spring retainer 3 Spacer 4 Stoplight switch 5 Brake...

Page 1143: ...sconnect the brake pipes from the master cylinder 4 Remove the wrap aroundclip and nut from the power brake unit master cylinder mounting stud 5 Remove in the order shown in the figure 6 Install in th...

Page 1144: ...ace the gauge on the mounting surface of the power brake unit as shown 3 The engine must be running with the vacuum line con nected to the power brake unit 4 Adjust the push rodscrew untilthe screwjus...

Page 1145: ...e air Referto page P 10 3 Check for leakage Refer to page P 13 Caution Secure the master cylinder in a vise when necessary Donotletforeignmaterialenterthecylinder anddo notscratchthe insideof thecylin...

Page 1146: ...n Do not attempt to hone the master cylinder if damage is found 4BUOPX 026 MP1081 C POWER BRAKE UNIT Quick inspection On vehicle Step 1 1 Push the brake pedal down 2 Start the engine 3 The brake pedal...

Page 1147: ...oval referringto lnstallation Note 6 After installation perform the following 1 Add fluid and bleed the air Refer to page P 10 2 Check for fluid leakage Refer to page P 13 3 Start the engine and check...

Page 1148: ...d is removed or acciden tally pulled out If the disc cannot be properly installed and aligned or cannot be located within MP1012 A 4BUOPX 032 the power brake unit itself the power brake unit must be r...

Page 1149: ...for leakage 3 Depress the pedal a few times then verify that the brakesdo not drag while rotatingthe wheels by hand FRONT OF VEHICLE I MP1128 A 1 Caliper Removal Note InstallationNote Disassemblyl Ins...

Page 1150: ...allation Note page P 26 3 Locknut 2 5BUOPX 019 4 Outer bearing assembly 5 Disc plate Removal Note page P 25 Inspection page P 26 Installation Note page P 26 6 Grease seal 7 Inner bearing assembly Remo...

Page 1151: ...or plate bolts and the anchor plate 5BUONX 020 Disc plate 1 Remove the grease cap from the hub 2 Remove the cotter pin retainer adjusting nut and flat washer from the spindle and discard the cotter pi...

Page 1152: ...the spindle 7 lnstall the adjusting nut Refer to Section M for wheel bearing adjustment 8 lnstall the retainer a new cotter pin and the grease cap 5BUOPX 022 Caliper disc pad 1 The caliper must be bot...

Page 1153: ...tion repair or replace the disc plate Standard 20 6mm 0 81 in 2 If the thickness is not within the specification replace the disc plate Rotor turning Note A 70mm 2 756 in gauge ball used in conjunctio...

Page 1154: ...be replaced 5 Checkthediscplatefor the maximumamountofstockthat can be removedfrom the disc plate Measurethe actual disc plate thickness with a micrometer and subtract the minimum allowablethickness c...

Page 1155: ...e figure referring to Disassembly Note 2 lnspect all parts repair or replace if necessary 3 Assemble in reverse order of disassembly MP1180 A 5BUOPX 123 1 Dust boot 3 Piston seal 2 Piston 4 Bleeder sc...

Page 1156: ...e reverse order of removal referringto lnstallation Note 5 After installation check the following 1 Add fluid and bleed the air Refer to page P 10 2 Check for fluid leakage Refer to page P 13 3 Depres...

Page 1157: ...ip or damage the MOVE DOWN notchesinthe adjustingscrewonthe self adjusting mechanism it will not function properly MOVE UPWARD TO RETRACT BRAKE SHOES I I MPI085 8 3 Remove the brake shoe trailing side...

Page 1158: ...Interchangingbrakeshoe adjusting screw assem blies from one side of the vehicle to the other will causethe brakeshoeto retract rather than expand each time the automatic adjusting mechanism is operate...

Page 1159: ...ly the brakes several times while driving the vehicle alternately forward and reverse When the rear brake shoes have been properly adjusted road test to check brake operation I Warning Only road test...

Page 1160: ...Inspection 1 Assembly Caution If a problem isfound inthe wheel cylinder housing or piston replacethe wheel cylinder as an assembly 1 Disassemble in order shown in the figure 2 Inspect all parts repair...

Page 1161: ...fter servicing iscompleted the cablesare connected to the equalizer and tension is reset Refertothe following proceduresfor releasingand resetting cable tension 1 Place the pedal in the released posit...

Page 1162: ...IS POSITION 1 Remove the parking brake pedal Refer to page P 38 2 Engage the coil spring on the tab on the wheel in the parking brake control 3 Placethe controlhandleinthe releasedpositionto unlock th...

Page 1163: ...of removal 7 Apply and release the parking brake several times to verify operation 5BUOPX 029 REAR PARKING BRAKE CABLE Removal1Inspection Installation 1 While an assistant relievestension on the syst...

Page 1164: ...the parking brake several times to verify correct operation Also verify the parking brake switch operation MP1133 A 1 Parking brake pedal REAR ANTI LOCK BRAKE SYSTEM RABS DESCRIPTION The Rear Anti lo...

Page 1165: ...REAR ANTI LOCK BRAKE SYSTEM RABS WIRING DIAGRAM...

Page 1166: ...em Input solenoid solenoid warning light warning light p p p 0 0 Brake On Off BOO swltch 0 I p p p p 0 L o O DIAGNOSTICCHART RABS test connector lgnltlon swltch Flu d level sensor I 0 Park ng brake sw...

Page 1167: ...gins to Self diagnosisfunction flash with the i nition switch ON IYellow rear ABS warning light remains illuminated with the ignitionswitch ON after one blinking illumination 1 7 1 Yellow rear ABS war...

Page 1168: ...nnectlon at RABS control unit I 3 l Check the resistance betweenterminal 4 Yes Go to next step LGIY of the RABS control unit connector and I ground 1 I 1 Resistance Less than i Q ilnspect related wiri...

Page 1169: ...ace the connector as needed Go to next step Firmly reconnect the fluid level sensor connector Turn ignition switch to START position Is the brake system warning light illuminated Yes Condition is reso...

Page 1170: ...ion switch ON 1 No Go to next step lnspect the brake system for leaks Fill the reservoirto specification Replacethe reservoir if needed Yes Reconnectthe RABS control unit Go to next step RABS control...

Page 1171: ...control unit harness connector OK page P 61 Yes Is the rear ABS warning light harness OK 3 Go to next step lnspect harness LBIP between fuse block Number 14 20A fuse and RABS control unit Replace the...

Page 1172: ...lecause RABS test connector shorted to ground Faulty wiring harness Faulty RABS control unit Self diagnosis function INSPECTION ACTION Is the flashing pattern a service code for connection to ground 1...

Page 1173: ...as needed Is the Brake On Off BOO switch the RABS control unit OK LGIR between RABS control unit and Brake OnIOff BOO switch Is the voltage of terminals 1 and 9 of the RABS control unit harness connec...

Page 1174: ...sing Stoplights inoperative Hydraulic unit failure Isolationvalve stuck closed hard pedal Dump valve leaky soft pedal Isolationvalve leaky during RABS stop soft pedal Vehicle electrical concern Stopli...

Page 1175: ...n switch cycles 5BUOPX 048 Inspection procedure 1 Locatethe RABS test connector Note The RABS diagnostic test connector is located behind the right hand kick panel The RABS rear speed sensor test conn...

Page 1176: ...hthe RABStest connector disconnected 2 Reconnect the RABS test connector 4BUOPX 088 1 ite 1 PossibleCause Patternof Output Signal Rear ABS Warning Light Diagnosis i Chart No RABS 2 j RABG j RABS 4 I I...

Page 1177: ...form memory cancel and recheck codes r 7 If service code 2 is still present replace RABS control unit If service code 16 is present concern has been corrected Drive vehicle and verify proper operation...

Page 1178: ...ck isolation valve orifice I Check for blocked orifice If all above are OK perform memory If servlce code 4 IS st111present cancel and recheck codes replace RABS control unlt If servlce code 16 IS pre...

Page 1179: ...ck codes 1 9 1 Perform memory cancel and recheck codes If service code 6 is still present replace RABS control unit If service code 16 is present concern has been corrected Drivevehicle and verify pro...

Page 1180: ...nal 3 RIP terminal 10 LGIB Check rear axle speed sensor If all above OK oerform memorv cancel Service code 10 I R A B I Check for poor connection Check for poor connection Check for open Check for pro...

Page 1181: ...nti lockstop Damaged brakefluid level sensor or related circuit Check item Remark Refer to I Check brake fluid level in reservoir Fill reservoir to specified level Check brake system for fluid leaks R...

Page 1182: ...ntermittent fault Note Codes can only be stored if the RABS control unit has power The RABS control unit gets primary powerfrom the Number 1420A fuse intoterminals 1 and 9 If the voltage is missing or...

Page 1183: ...the test No I 4 1 Have all the circuits in question for the code being serviced been tested Service the connectors and terminals as needed Go to step 5 Go to step 4 1 Yes Check for service codes Is c...

Page 1184: ...ess for short to ground BASE INSTRUMENT CLUSTER REAR ABS WARNING LIGHT I i MP1134 A 5BUOPX 062 Check rear ABS warning light bulb 1 Remove the instrument cluster 2 Removethe warning light bulbfrom the...

Page 1185: ...and the RABS control unit Check parking brake switch Refer to the 1996 B series BETM 6BUOPX 011 Check fluid level sensor Refer to page P 20 Check ignition switch bulb prove out circuit Referto the 19...

Page 1186: ...ess the brake pedal hard enough to lock all wheels 3 After the vehicle has stopped place the vehicle in Park AT or Neutral MT and take foot off of the brake pedal and wait 30 seconds 4 If the rear ABS...

Page 1187: ...ed e Ignition switch ONISTART Fluid level sensor lgnition switch in START or brake fluid level low arounded 0 3 LGlB Rear axle speed sensor Rear wheels stopped Measure AC voltage between terminals 3 a...

Page 1188: ...ct the rear axle speed sensor connector 2 Check resistance at the rear axle speed sensor Resistance 0 9 2 5 kQ Check voltage of rear axle speed sensor 1 Jack up the vehicle and support it on safety st...

Page 1189: ...32 kmlh 20 mph 3 Perform a light to medium stop 4 If the rear wheels lock up inspect the conventional brak ing system 4BUOPX 132 Dry road lock up test 1 Drive the vehicle at approximately 16 kmlh 10...

Page 1190: ...em Refer to page P 10 Note It is not necessary to energize the hydraulic unit electronically to bleed the rear brakes Before connecting the RABS hydraulic unit con nector fill the unit side connector...

Page 1191: ...R RABS AND ABS RemovalI lnstallation 1 Disconnect the connector from the speed sensor 2 Remove the bolt and remove the speed sensor from the axle housing 3 Install in reverse order of removal referrin...

Page 1192: ...ring must be discarded upon removal If removed a new speed sensor rotor must be installed 5 Install in reverse order for removal referring to Installation Note 5BUOPX 082 Removal Note Ring gear Remove...

Page 1193: ...ring gear retaining boltswith sealant Install bolts and alternately tighten evenly Tightening torque 95 1 15 N m 9 7 1 1 7 kgf m 70 45 ft lbf Inspection 1 Remove the speed sensor Refer to page P 65 2...

Page 1194: ...e and on all B4000vehicles The 4WABS control unit senses the drop in wheel speed and modulates hydraulic pressureto all four brakes inhibiting lock up 6BUOPX 014 TROUBLESHOOTING GUIDE Outline The ABS...

Page 1195: ......

Page 1196: ...4 WHEEL ANTI LOCK BRAKE SYSTEM 4WABS WIRING DIAGRAM...

Page 1197: ...ual inspection Hook up SST NGS to vehicle 1 2 Select VEHICLE AND ENGINE SELECTION 1 3 Select SELECT NEW VEHICLE YEAR MODEL I MJ1173 A 4 Select DIAGNOSTIC DATA LINK VEHICLE 6 ENGINESELECTION VlEW RECOR...

Page 1198: ...NEW VEHICLE YEAR MODEL I NO VEHICLE SELECTED DESELECTCURRENTMODEL 111 1 I J SELECT ITEMAND PRESSTRIGGER TO START i I I 1 1 7 3 A i i 4 Select DIAGNOSTIC DATA LINK I J SELECT ITEMAND PRESS TRIGGER TO...

Page 1199: ...1 P 82 P 84 P 86 P 88 P 90 P 92 P 94 P 96 P 96 P 96 P 100 P 102 P 102 P 102 P 106 P 108 p p p p PinpointTest ReplaceAnti Lock Electron c Control Module A B B1317 Battery Voltage High Key ON C 8131 8 t...

Page 1200: ...l I OFF 17 29 ABS Warnrng Lrght Ground Through I OFF 17 1 System Relay t IFR lsolat on Inlet Valve Resrstance 1 OFF 17 34 IFL lsolatron Inlet Valve Resrstance I OFF 17 40 IRA lsolatron Inlet Valve Res...

Page 1201: ...free of corroslon and excessive dlrt Are all connectlonssecure and fuses OK 2 Verlfy that the 3 pln acceleration sensor connector 4x4 only 0 1 008 and the 2 pln rear axle sensor connector 0 1 010 are...

Page 1202: ...test hght between 4WABS warnlng l ght bulb socket and a known good chassis ground Remove4WABS main relay Verify relay terminals are clean and firmly in place Check for continuity between 4WABS main re...

Page 1203: ...ing on the COMPONENT side of the hydraulic unit pin connector Pin 1 and valve block Pin 4 and valve block Note The valve resistance will change rapidly Is measured resistanceless than 10 000ohms at an...

Page 1204: ...N Measure voltage at breakout box pin 17 No 1 Go to step 4 Is voltage between 9 5 and 18 volts and w thln 5 volt of battery voltage 1 Key OFF Yes Go to step 3 I Fieconnectcontrol unit Key ON Is ABS li...

Page 1205: ...in circuit TIY Is resistance less than 1 ohm circuit TIY Go to step 14 p p 9 Key OFF Yes Go to step 10 Check for ground short at circuit PILG breakout box p p p p No Repair or replace circuit PILG for...

Page 1206: ...usedby many towing services i I Has the vehicle been jump started by a towing service G o oto step 2 within the past two weeks I I Description PossibleCause Key ON engine running Measurevoltage at 60...

Page 1207: ...in circuit LBIP to pin 20 1 STEP INSPECTION ACTION system for undervoltage I I condition CONITINUOUS DTCS Is B1318 battery voltage low present BATTERY VOLTAGE LOW 1 Yes GOto step 3 A new code is pres...

Page 1208: ...7 and 40 Yes Go to step 5 Terminal backout in hydraulic unit connector pins 1 4 and 6 Open or shorted inlet front left IFL valve coil Open or shorted driver in control unit P I INSPECTION ACTION No Go...

Page 1209: ...eakout box with overlay Repeat step 1 while driving vehicle Look for any changes in indicated continuity Inspect circuits OIY and T along their entire length from the sensor connector to the control u...

Page 1210: ...hydraulrc unit Measure res stance between pins 1 and 7 and pins 4 and 1 connector and control unit connector 7 on the hydraulic unlt I Install relay Are both readlngsbetween3 and 6 ohms7 Go to step 4...

Page 1211: ...o step 3 A new code is present Go to appropriate pinpoint test Code C1194 is present and control unit has been replaced Note 4WABS is disabled with the breakout box installed Install breakout box with...

Page 1212: ...is or any other system component without specific directionwill not in most circumstances resolvethe concern and will consequently result in customer dissatisfaction RIGHT FRONT IS0 VALVE COIL CIRCUIT...

Page 1213: ...le Look for any changes in indicated continuity Inspect circuits OIY and W along their entire length from the sensor connector to the control unit harness connector for chafing or any other damage tha...

Page 1214: ...n hydraulic unit connector Verify terminals on both halves of the hydraulic unit 8 way connector are clean and secure Measure resistance between pins 1 and 5 and pins 4 and 5 on the valve block Are bo...

Page 1215: ...t Go to step 3 A new code is present Go to appropriatepinpoint test Code C1210 is present and control unit has been replaced Note 4WABS is disabled with the breakout box installed Installbreakout box...

Page 1216: ...unit connector Verify terminals on both halves of the hydraulic unit way connector are clean and secure Measure resistance between pins 1 and 2 and pins 4 and 2 on the valve block Are both readingsbe...

Page 1217: ...ing NGS Tester clear all DTCs Go to step 5 Key OFF Key ON Code C1206 is present I Go to ster I Uslng NGS Tester perform RETRIEVEICLEAR 1 CONTINUOUS DTCS I Dld system pass Go to step 3 A new code IS pr...

Page 1218: ...nostic trouble code has Remove main relay Repair or replace open or short ground in circuits P and ON between hydraulic unit connector and control unit connector Install relay Go to step 4 Key OFF yes...

Page 1219: ...y Repeat step 1 while driving vehicle Look for any changes in indicated continuity Inspectcircuits P and OIY along their entire lengthfrom the sensor connector to the control unit harness connector fo...

Page 1220: ...reakout box and wheel speed sensor harness connector pin for circuit T O Is there continuity zero or near zero ohms Measure resistance between pin 25 on the breakout box and wheel speed sensor harness...

Page 1221: ...lled Install breakout box with overlay Repeat step 3 6 while driving vehicle Look for any changes in indicated continuity 10 most likely cause of the concern is wiring related Refer to the Intermitten...

Page 1222: ...unnecessary component replacement and wasted idiagnosis time 7 I Yes ACTION Rlng gear IS damaged or mtsslng Replace rlng gear Go to step 5 to check for proper sensor output Sensor is loose Tighten sp...

Page 1223: ...Feeler gauges can be mounted to a welding rod and inserted between the vanes of the front disc brake hub and rotor to measure the gap precisely Is the gap consistent and less than 1 78 Place in 4x4 l...

Page 1224: ...de belng servlced st111 exlsts Drrve vehlcle and perform the following Go to step 8 Complete at least one hard left and one hard rlght turn Drfferent code IS present Travel over a stretch of rough roa...

Page 1225: ...pins on the speed checks good sensor component connector Is reading between 1 O 1 4 kQ Measure resistance between pin 23 on the breakout box Yes Circuit YIB checks OK and wheel speed sensor harness c...

Page 1226: ...ndicated contlnulty Inspect clrcuits YIR and YIB along thew i entire length from the sensor connector to the control unlt harness connector for chaflng or any other damage that could leadto any open o...

Page 1227: ...that the air and speed sensor strength are OK Go to step 7 I Inspectthe rlght front sensor rotor for any damaged or missing teeth I Rotatewheel to ensure all teeth are checked I Inspectthe speed senso...

Page 1228: ...aight or axle end play is too great Go to step 6 _ Yes Output IS now OK Concern IS most llkely resolved A drlve test IS recommend to verlfy sensor output IS OK for customer drlvlng condltlons Refer to...

Page 1229: ...umstances resolvethe concern and will IGo to last diagnostic step completed and consequentlyresult in consumer dissatisfaction continue Have all prior diagnostic steps been completed as described abov...

Page 1230: ...s e e d sensor harness connector pin for circuit RIP Is there continuity zero or near zero ohms Yes j Circuit RIP checks OK 1 Go to step 4 No Repair open or high resistance on circuit RIP I I I GOto...

Page 1231: ...ed as described above Key ON Using NGS Tester clear all DTCs Key OFF Key ON Using NGS Tester perform RETRIEVEICLEAR CONTINUOUS DTCs Did system pass No No Go to last diagnostic step completed and conti...

Page 1232: ...record the frequency between pins 21 and 22 on breakout box Measure and record the voltage output between pins 21 and 22 on breakout box Note Measurements of BOTH the frequency and the voltage output...

Page 1233: ...perform for circuits RIP and LGIB Is resolutionachieved This step requiresthat a valid diagnostictrouble code has been obtained ALL prior diagnostic steps have been completed and the affected wiring i...

Page 1234: ...o page P 11 Ra se vehlcle so front left wheel IS just off the ground Press hard on the brake pedal and have an ass stant try to turn the LH front wheel Note This condition is similar to the master cyl...

Page 1235: ...15 19 34 and 1 together on the breakout box 1 Refer to page P 11 Raise vehicle so front right wheel isjust off the ground Press hard on the brake pedal and have an assistant try to turn the RH front w...

Page 1236: ...19 27 33 and 1 together on the breakout box Refer to page P 11 Raise vehicle so rear wheels are just off the ground Press hard on the brake pedal and have an assistanttry to turn a rear wheel Note Th...

Page 1237: ...partment fuse box battery and ground connections relay connections and pump motor connections Remove control unit install60 pin breakout box and overlay Verify ground Jumper pins 1 and 19 together Key...

Page 1238: ...it ON i and main relay circuit ON I Is there continuity Repair circuit ON Go to step 9 6 MP9654B2 7BUOPX 004 Disconnect battery negativecable yes GO to step 7 Check continuity from pump motor relay ci...

Page 1239: ...n consumer dissatisfaction Have all prior diagnostic steps been completed as described above Replace pump motor relay Go to step 8 Repair open in circuit PILEI Go to step 9 Replacecontrol unit Go to s...

Page 1240: ...ebetween G switch pin 2 and pin 3 Are both resistancesmeasuredless than 5 ohms STEP INSPECTION I ACTION I No All switches should be closed ReplaceG switch Go to step 11 Yes No Raise the front of the G...

Page 1241: ...ictrouble code has been obtained ALL prior diagnostic steps have been completed and the affected wiring integrity has been verified CAUTION If the above is not complete chances are that replacement of...

Page 1242: ...solutionachieved Key ON Jumper breakout box pins 1 and 19to energize main relay Verify that contacts are not sticking or welded Is pump motor running This step requires that a valid diagnostic trouble...

Page 1243: ...age between breakout box pins 1 and 16 at B shall on circuit breakout box Is B present unit and Data Link Connector i 1 Go to step 3 in System Precheck 1 Is there continuity at both pins 1 3 Key OFF y...

Page 1244: ...han 10 ohms or replace as necessary 1 Go to step 3 in System Precheck I I 6 Yes KeyON Measure voltage between pins 20 and 1 Is there at least 9 5 volts Replace control un t Go to steD 3 In Svstem Prec...

Page 1245: ...6 ABS llght IS not on Go to step 2 Check for Unwarranted ABS Activity Yes ABS light is not on Drive Perform vehlcle a light atto approx mately medlum I normal 32 kmlh trafflc 20 stop mph Check go to...

Page 1246: ...st Code obtained is not same Go to appropriate pinpoint test No DTC or system pass obtained Go to System Precheck INTERMITTENT DIAGNOSTICPROCEDURE Note An understandingof DTC storage and automatic DTC...

Page 1247: ...look for Bent terminals Damaged connector terminal locks Damagedconnector wedge Note If one of the above conditions is found Repair connector and terminal as necessary Go to step 5 check the tightnes...

Page 1248: ...ingcomponents in the order shown 5 Install in the reverse order of removal referringto lnstallationNote 6 Bleed the brake system Refer to page P 11 I FRONT OF VEHICLE 15 20 1 I 11 14 ___ _ __ MP1118 A...

Page 1249: ...e battery tray 1 Removethe battery 2 Disconnectthe harness connector and remove the screw from the control unit 3 Remove the control unit 4 Install in the reverse order of removal referring to lnstall...

Page 1250: ...sor rotor 1 Pressthe new speed sensor rotor on the disc plate using a cylinder with a 79mm 3 1 in ID and a 96mm 3 8 in OD 5BUOPX 032 i 1 MP1120 A 5BUOPX 031 FRONT SPEED SENSOR Removal 1 lnstallation 1...

Page 1251: ...NS Q 2 TROUBLESHOOTING GUIDE Q 3 WHEELS AND TIRES Q 4 SPECIAL NOTES ABOUT WHEELS AND TIRES Q 4 NOTES REGARDING TlRE REPLACEMENT Q 4 IIVSPECTION ADJUSTMENT Q 4 REMOVAL INSTALLATION Q 6 TIRE ROTATION Q...

Page 1252: ...OUTLINE OUTLINE SPECIFICATIONS Standard Tire 7 4x2 Regular Cab 2892 I143 2077 4580 4x4 Regular Cab Size Offset and Pitch Circle Diameter Refer to page TD 26 e...

Page 1253: ...djust Replace Replace Replace Tighten Adjust Shake occurs steeringwheel vibrates upldown Cracked or worn transmission mount rubber Shimmy occurs steeringwheel vibrates circurnferentially Excessivetire...

Page 1254: ...r foreign items embedded in the tire tread 5 Be sure the air valve is installed correctly 6 Apply a soapy solution to the tire bead and the edge of the rim before mounting 7 After mounting a tire onto...

Page 1255: ...ires p p p Adiust toe in d lncorrect camber or caster Malfunctioning suspension Unbalancedwheel I Out of roundbrake drum or disc Other mechanical problem Lack of rotation Incorrecttoe ln Repair or rep...

Page 1256: ...longtire lifeandassure uniformtirewear rotatethe tires every 8 000 12 000 km 5 000 7 500 miles Caution Usethe best tires on the front axle After rotating the tires adjust each tire to the specified ai...

Page 1257: ...AN ADJUSTMENT INSPECTION DIAGNOSIS FRONT WHEEL ALIGNMENT FRONT SUSPENSION FRONT SHOCK ABSORBER 4x2 AND 4x4 FRONT COlL SPRING 4x2 FRONT COIL SPRING 4x4 LOWER ARM AND PIVOT BRACKET 4x2 PIVOT BRACKET 4x4...

Page 1258: ...Installation page R 27 2 Front coil spring 6 Front stabilizer bar Removal I InspectionI Removal Inspection1 Installation page R 18 Installation page R 30 3 Lower arm and pivot bracket 7 Jounce bumper...

Page 1259: ...Installation page R 20 3 Pivot bracket Removal Inspection Installation page R 24 4 Camberlcaster adjuster Removal Inspection Installation page R 26 I 5BUORX 003 5 Radius arm Removal Inspection Instal...

Page 1260: ...ON 4x2 AND 4x4 MR1001 A 4BUORX 004 1 Rear shock absorber 3 Rear stabilizer bar Removal Inspection Removal Inspection Installation page R 33 Installation page R 38 2 Leaf spring Removal Inspection1 Ins...

Page 1261: ...gle rnax C 60 I 6 I T r l I Caster split I 1 0 f 4 1 MR1002 C 6BUORX 001 Note When the battery has beendisconnected and reconnected some abnormal olrive symptoms mayoccurwhilethe powertraincontrolmodu...

Page 1262: ...ection Q Section Q R 27 R 18 20 R 35 Section d R 18 20 R 35 R 16 Heavy steering Worn ball jo nt Replace Sect on M Improperly adjusted wheel al gnment Adjust I R 9 I Malfunction of steering system I 1...

Page 1263: ...ated STEP 3 ISOLATE NOISE CONCERN If the noise can be duplicated by pushing up and down on the vehicle while stationary Use a stethoscope or chassis ears to determine the area of the chassis that the...

Page 1264: ...of bolt on both LH and RH side If not install washer under head of bolt Tlghten fasteners to speclfled torque Replace bushlngs Tlghten fasteners to speclfled torque Replace shock absorber Replace bus...

Page 1265: ...s are filled 6 lnspectthe front wheel bearing play Replacethe bearing if necessary 7 lnspect the wheel and tire runout 8 Check that the steering linkage and radius arm are not bent or damaged Replace...

Page 1266: ...ht front ride heights Note On 4x2 models add 8mm 0 3125 in to the right side ride height measurement On 4x4 models add 12mm 0 5 in to the left side ride height measurement RIDE HEIGHT MR1053 A 2 If th...

Page 1267: ...he rear of the vehicle can be adjusted by approximately6mm 1 1 1 4 in by install inga shim betweenthe rear spring1and axle on the low side of the vehicle A low at the rear vehicle can be raised approx...

Page 1268: ...6mm 518 in variance between left and right front wheel lips to ground Maximumof 20mm 314 in variance betweenleft and right rear wheel lips to ground I I MR1057 A 6BUORX 007 1 Pre are the Preins ection...

Page 1269: ...ch marks are for the front tires and which marks are for the rear tires 6 Movethe vehicle out of the way so all of the marks can be seen 7 Proceed to measure the total amount of dogtracking as follows...

Page 1270: ...determine the amount of camber and caster in the adjuster that is installed in the vehicle Note The degreesof camber and caster are stamped on the top of the production adjuster For the right side of...

Page 1271: ...Ibf CamberICaster Adjuster SelectionTable 1 0 1 4 c G O O 1 l 8 Install a new camberlcaster adjuster snap ring on 4x4s with a Dana 35 axle 9 Installthe front wheels 10 Check the alignment I LH Side Po...

Page 1272: ...o open puncture or apply heat to the shock absorber 1 Jack up the front of the vehicle and support it on safety stands 2 Remove the front wheels 3 Remove in the order shown in the figure 4 Inspect all...

Page 1273: ...n and the shock should be replaced 4 If a shock absorber is suspected of being weak compare the compression results with the opposite side If the action is similar it is unlikelythat either shock abso...

Page 1274: ...ct the shock absorber from the lower shock stud 4 Remove in the order shown in the figure referringto Removal Note 5 Inspect all parts and repair or replace as necessary 6 Install in the reverse order...

Page 1275: ...the brakehose These 1 0 4 7 A BUORX 018 precautions are absolutely necessary to prevent serious damage to the tube portion of the caliper hose assembly 1 Lower the lower arm ar d support it without s...

Page 1276: ...elow Installation Note page R 21 Removal note Coil spring Caution Thelowerarmor axlecasingmust besupportedon a jack throughout the spring removaland installa tion procedure The lower arm or axle casin...

Page 1277: ...use Strut Spring Compressor T81P 5310 A or equivalent 3 If required remove the stud from the lower arm or axle casing Installationnote Coil spring 1 If removed install the axle stud Tightening torque...

Page 1278: ...Removal Note 6 Inspect all parts and repair or replace as necessary 7 Install in the reverse order of removal referringto lnstallation Note 150 200 15 3 20 4 FRONT OF VEHICLE RH LOWER ARM INSTALLATION...

Page 1279: ...or equivalent between the walls of the axle 4 Using Forcing Screw T78P 5638 A1 Pivot Bushing Remover 1801 5638 A2 and Receiver Cup T78P 5638 A3 or equivalents remove the pivot bushing Installation no...

Page 1280: ...iner Removal Note page R 25 3 Lower retainer InstallationNote page R 25 4 Pivot bracket Removal Note below InstallationNote page R 25 Removal note Pivot bracket 1 Lowerthe hoistuntiltheaxlecasingisinc...

Page 1281: ...bushing 1 Using Receiver Cup T78P 5638 A4 Forcing Screw T78P 5638 A1 or equivalents and either Bushing Replacer T82T 3006 A Dana 28 or Front Suspension Bushing Tool T80T 5638 A Dana 35 or equivalents...

Page 1282: ...lt and nut Tightening torque 150 200 N m 15 3 20 4 kgf m 111 1 48 ft lbf CAMBER I CASTER ADJUSTER 4x2 AND 4x4 Removal IInspection1 Installation 1 Jack up the front of the vehicle and support it on saf...

Page 1283: ...the spindle Refer to Section P Aft r removal the caliper must be placed on the frame or otherwise supported to prevent suspending the caliper from the brake hose These precautions are absolutely nece...

Page 1284: ...shock absorber from the shock lower stud 4BUORX 038 Radius arm 4x2 Note The rear washer shield is only on the right side on models with 3 OL and 4 OL engines 4BUORX 039 Radius arm 4x4 Loosenthe lower...

Page 1285: ...1 53 N m 11 5 1 5 5 kgf m 83 1 13 ft lbf 2 lnstall the stud Tightening torque 255 345 N m 26 2 35 2 kgf m 1 88 254 ft lbf 3 lnstall the front bracket bolt Tightening torque 21 29 N m 2 1 2 9 kgfam 15...

Page 1286: ...shown in the figure 5 lnspect all parts and repair or replace as necessary 6 Installin the reverse order of removal referring to lnstallationNote 1 Washer 2 Stabilizer bracket 3 Bushing lnspectfor da...

Page 1287: ...lace as necessary 5 Install in the reverse order of removal referringto lnstallationNote I LH JOUNCE BUMPER RH JOUNCE BUMPER N m kgf m ft lbfl 1 Hex bolts Removal Note below Installation Note below 2...

Page 1288: ...ce as necessary 5 Install in the reverse order of removal referringto lnstallation Note LHJOUNCE BUMPER RH JOUNCE BUMPER N m kgfm ft lbf MR1081 A 5BUORX 048 1 Hex bolffnut Removal Note below Installat...

Page 1289: ...ve the shock absorber lower attachingnut and bolt and swingthe lower end free of the mounting bracket on the axle housing 4 Remove the attaching nut from the upper mounting bolt Remove the shock absor...

Page 1290: ...should be replaced 4 If a shock absorber is suspectedof beingweak compare the compression results with the opposite side If the action is similar it is unlikely that either shock absorber is worn or d...

Page 1291: ...er shown in the figure referringto Removal Note 4 Inspect all parts and repair or replace as necessary 5 Install in the reverse order of removal referringto InstallationNote PLATE 4x21 isf6 BE INSTALL...

Page 1292: ...l clearance for insertion of the liners 2 Slide the liner between the leaves until the liner extends approximately 6 35mm 0 25 in beyond the tip of the lower leaf Note Do not attempt to install the li...

Page 1293: ...ttheoutersurfaceof the legsisflushwith the leaf spring sides 7 Placethe rubberserviceclip lineracrossthe top of the leaf spring Align the lowerclip with the flat surface againstthe leaf and the clip l...

Page 1294: ...5 Installin the reverse order of removal referringto lnstallation Note N m kgfm ft lbf MR1041 C 5BUORX 044 1 Mounting bracket 3 End link 2 Retainer 4 Stabilizer bar Inspect bushingfor damage and crack...

Page 1295: ...WINDSHIELD S 34 COMPONENTS S 34 REAR WINDOW GLASS S 37 COMPONENTS S 37 TRIM S 40 COMPONENTS S 40 FLOORMATICARPET S 45 HEADLINER S 47 SEAT BELTS S 49 FRONT SEAT S 49 REAR SEAT S 52 BOX CAB AND BOX ALIG...

Page 1296: ...page S 7 7 Windshield 2 Fender panel RemovalI Installation page S 34 Removal I Installation page S 9 8 Trim 3 Front door RemovalI Installation page S 40 Removal Installation page S 11 9 Weatherstrips...

Page 1297: ...r lid 8 Splash shields not shown Removal Installation page S 17 Removal Installation page S 32 4 Molding Removal Installation page S 30 5 Rear window glass Removal Installation page S 37 Note When the...

Page 1298: ...egative battery cable 2 Open the hood and prop the hood in the open position 3 Cover the cowl area to prevent paint damage 4 Remove in the order shown in the figure referringto Removal Note 5 Install...

Page 1299: ...arnessconnector and remove the wiring from the hood 3 Remove the hood light 4 Remove the hood insulator 5 Withthe aidof an assistant holdthe hooldand removethe hinge to hoodbolts 6 Remove the hood Hoo...

Page 1300: ...he releasecable bushingto the dashboard install it from the inside of the vehicle 3 Securethe release cable to the steering column support bracket with the bundling strap 4 Installthe release cable to...

Page 1301: ...Hood I lnstall the hood light 2 lnstall the hood insulator 3 Withtheaidof anassistant positionthe hoodtothe hinges and install the bolts Tightening torque 7 10 N m 0 7 1 1 kgf m 5 43 ft lbf 4 lnstall...

Page 1302: ...igned with the hood lock striker and tighten the bolts to the specified torque Tightening torque 10 5 1 3 5 N m 1 1 1 3 kgf m 8 1 0 ft Ibf 3 Check the lock assembly to make sure it makes full engageme...

Page 1303: ...diatorgrille Refer to page S 23 3 Remove in the order shown in the figure 4 Install in the reverse order of removal referringto lnstallation Note N m kgf m ft lbf MS1008 B 4BUOSX 016 1 Splash shield 3...

Page 1304: ...ing torque 10 8 13 5 N m 1 I 1 3 kgf m 8 10 ft lbf 4BUOSX 018 Splash shield Installthe splash shield Tighteningtorque 10 8 13 5 N m 1 l 1 3 kgf m 8 10 ft lbf Inspection Fender panel 1 lnspect the clea...

Page 1305: ...order of removal referring to lnstallationNote N m kgf m ftalbf I I MS1011 A 4BUOSX 021 1 Front door 2 Door hinge Removal Note below Removal Note page S 12 Installation Note page S 12 Installation No...

Page 1306: ...hinge 1 Mark the location of each hinge on the body 2 Remove the hinge 4BUOSX 023 InstallationNote Door hinge Install the door hinge Tightening torque 25 34 N m 2 5 3 5 kgf m 18 4 25 8 ftelbf 4BUOSX...

Page 1307: ...lushof thefront doorto the A pillar from point X to point Y refer to the figure 4 0mm 0 157 IN PILLAR L Underflush 6 1 0 5 0mm 0 04 4 1 9 in 7 If the door is not adjustedproperly loosenthe front door...

Page 1308: ...r to below 3 Install in the reverse order of removal I MSlO14 B 4BUOSX 027 1 Front door lower weatherstrip 2 Front door opening weatherstrip 3 Roof side rail weatherstrip QUARTER WINDOW Removal Note Q...

Page 1309: ...te page S 16 4 Support cable Inspection page S 16 Removal Note Tailgate 1 Open the tailgate 2 Partiallyclosethetailgateto relievetension onthesupport cables 3 Pull up on the cable retainer spring and...

Page 1310: ...next insert the right side into the right hinge 4 Support the tailgate to allow slack in the support cables and reattachthe cables one at a time 4BUOSX 031 Inspection Tailgate clearances I lnspect the...

Page 1311: ...in the reverse order of removal 1 I MS1016 A 4BUOSX 033 1 Fuel fillerlid lnspection below 2 Fuel fillerlid spring Inspection Fuel filler lid Inspect the clearance and the flushness of the fuel filler...

Page 1312: ...val Note below Disassembly Assembly page S 19 Installation Note below Removal Note Front bumper 1 Support the front bumper 2 Remove the four front stud plate to frame nuts 3 Disconnect each turn signa...

Page 1313: ...nt bumper and the radiator grille Clearance 2 19 8 31 8 0 78 1 25 in Disassembly Assembly 1 Disassemble in the order shown in the figure referringto Disassembly Note 2 Assemble in the reverse order of...

Page 1314: ...Removal Installation 1 Remove the front grille 2 Remove any residual pieces of the bumper stripe Note Use heat gun to soften the stripe during removal Caution Avoid scratching the chrome surface of t...

Page 1315: ...tionNote below Removal Note Rear bumper 1 Support the rear bumper 2 Remove the rear bumper inner arm to framebolts 3 Remove the rear bumper lnstallationNote Rear bumper Installthe rear bumper Tighteni...

Page 1316: ...er outer arm 2 Rear bumper inner arm Assembly Note below Assembly Note below Assembly Note Rear bumper inner arm Install the rear bumper inner arm Tightening torque 113 0 153 0 N m 11 I 5 6kgf rn 8 3...

Page 1317: ...1 Radiator grille Inspection page S 24 Removal Note below Disassembly Assembly page S 24 InstallationNote below 2 Radiator opening cover if equipped Removal Note Radiator grille 1 Remove the bolts 2...

Page 1318: ...arker light assembly Clearance 2 3 0 7 0mm 0 124 27 in 3 lnspect the clearance between the radiator grille and the inboard side of the headlamp Clearance 3 0 0 13 5mm 0 0 4 53 in 4 lnspectthe clearanc...

Page 1319: ...OSX 056 1 Deflector EXTRACTOR CHAMBER COMPONENTS Removal l Installation 1 Remove in the order shown in the figure 2 Install in the reverse order of removal I I MS1023 B 5BUOSX 032 1 Front door trim 2...

Page 1320: ...ning cover 5 Instrument cluster Refer to 1997 BETM Removal Note below 6 Ash receptacle Installation Note page S 28 Installation Note page S 28 3 Steering column opening reinforcement 7 Passenger air b...

Page 1321: ...onnect three electrical connectors and ground strap at lower right handdashboard area 13 Remove lower steering column pinch bolt 14 Disconnect Brake On Off BOO switch connector 15 Remove three bolts a...

Page 1322: ...el Tightening torque 2 1 2 8 N m 21 38 kgfecm 18 26 in lbf 5BUOSX 040 Steering column opening reinforcement lnstall the steering column opening reinforcement Tightening torque 10 8 13 56 N m 1 l 1 38...

Page 1323: ...e below 4 Console mounting bracket Note below InstallationNote below lnstallation Note Console mounting bracket lnstall the console mounting bracket Tightening torque 7 1 1 N m 0 7 1 1 kgf my 5 1 4 0...

Page 1324: ...r of removal referring to lnstallation Note REGULAR CAB CAB PLUS L 1 MS1027 C 5BUOSX 065 1 Wheel opening moldings 3 Quarter window stationary molding Removal Note page S 31 Removal Note page S 31 Inst...

Page 1325: ...olding 1 Remove the necessary interior trim from around the window to gain access to the quarter window nuts 2 Remove the quarter window nuts 3 Remove the molding 4BUOSX 072 Installation Note Quarter...

Page 1326: ...stall in the reverse order of removal referring to lnstallation Note 1 Front wheel opening splash shield lnstallation Note below lnstallation Note Front wheel opening splash shield Install the front w...

Page 1327: ...reverse order of removal referring to lnstallation Note MSI035 A I 4BUOSX 081 1 Rear wheel opening splash shield lnstallation Note below lnstallationNote Rear wheel opening splash shield Install the r...

Page 1328: ...blocks under the headliner to move it away from the windshield and to prevent damage 6 Remove in the order shown in the figure referring to Removal Note 7 Install in the reverse order of removal refe...

Page 1329: ...ft open to prevent damage to the windshield from th pres sure created when closing the doors 1 Remove any remaining urethane from the windshield 2 Apply body primer to the outer surface of the flange...

Page 1330: ...ct moldingfit maintaina maximum of Imm 04 in difference between side margins 8 Installthe windshield and press it in slightly to compress MS1040 A 5BUOSX 046 the adhesive 9 Use a spatula to smooth awa...

Page 1331: ...e figure referringto Removal Note 2 Install in the reverse order of removal referringto lnstallation Note I I MS1095 A 5BUOSX 047 1 Rear window glass sliding glass 2 Rear window glass stationaryglass...

Page 1332: ...s retaining the anchor plate in the window track and remove the plate 5 Spreadthe windowframe andwork the movableglass out of its track and remove it from the frame 6 If the stationary glass is to be...

Page 1333: ...Spread the frame slightly and install the movable glass into the track 5 Positionthe anchor plate in the window track and install the screws 6 Installthe division bar upper screw 7 Position the weathe...

Page 1334: ...the 6 pillar trim Cab Plus referringto Removal Note Refer to page S 42 6 Remove the front door trim referringto Removal Note Refer to page S 42 7 Remove the lower back trim Cab Plus referringto Remov...

Page 1335: ...TRIM B pillar trim Regular Cab 1 Remove the A pillar trim MS1047 A 3 Remove the scuff plate 4 Remove the seat belt attachment from the floor MS1094 A 9 5 Remove the B pillartrim...

Page 1336: ...hment from the floor 6 Remove the jack cover 7 Remove the utility tray 8 Remove the B pillar trim Front door trim 1 Disconnect the negative battery cable 2 Removethe screws retainingthe armrest areaof...

Page 1337: ...ntrol if equipped 7 Carefully prythe door trim away from the door usingTrim Pad Removing Tool 107 00401 or equivalent 8 Remove the front door trim Lower back trim Cab Plus 1 Remove the B pillartrim 2...

Page 1338: ...t belt bolt to the specified torque Tightening torque 29 740 2 N m 3 1 4 1 kgf m 21 9 29 7 ft lbf B pillar trim Regular Cab Tighten the seat belt bolt to the specified torque Tightening torque 29 7 40...

Page 1339: ...smission remove four gearshift lever opening shield screws On Cab Plus remove retaining screws in top surface of rear step section 7 Remove the B pillar trim Cab Plus only Refer to page S 42 8 Removet...

Page 1340: ...CAB PLUS 1 CARPET MAT SIMILAR...

Page 1341: ...Removethe rear window garnish lower molding referringto Removal Note Refer to page 5 48 7 Removethe B pillartrim Refer to page S 41 for Regular Cab or page S 42 for Cab Plus 8 Removethe dome lamp lens...

Page 1342: ...060 A 4BUOSX 106 A pillar trim Remove the left and right side A pillar trim Rear window garnish lower molding Remove the rear window garnish lower molding Installation Note Headliner Preshape the new...

Page 1343: ...of removal referringto lnstallationNote Caution Do not disassemblethe buckle or retractor assembly BENCH SEAT 29 740 2 3 14 1 21 9 29 7 I Front seat belt 3 Shoulder height adjuster Inspection page S 5...

Page 1344: ...MS1097 A 5BUOSX 057 1 Front seat belt 3 Shoulder height adjuster Inspection page S 51 Removal Note page S 51 InstallationNote page S 52 Installation Note page S 52 2 Front seat belt buckle Installati...

Page 1345: ...al Note Shoulder height adjuster 1 Pull B pillartrim away from sheet metal to access height adjuster 2 Removeplastictrimfromadjusterbygraspingtrimon both sides of adjuster at center and pull inboard 3...

Page 1346: ...y install 1 lower attaching bolt and 2 upper attaching bolt 3 Tighten bolts Tighteningtorque 29 740 2 N m 3 14 1 kgf m 21 9 29 7 ft lbf 4 Position plastic trim over adjuster On regular cab the flange...

Page 1347: ...hat the belt can be pulled out smoothly and that it moves smoothly when worn 2 Verifythat the retractorlockswhen quickly pullingthe belt 3 Remove the retractor 4 Hold the retractor as it is installed...

Page 1348: ...e sure cab to box marginat outboardedge of box is no lessthan 21 0mm 0 826 in Less than minimum clearance may result in cab to box contact during severe usage 2 Move box so front of box is centered on...

Page 1349: ...826 in 6 Move cab and box to achieve proper alignment 0 REGULAR CAB MS1088 A 6BUOSX 010 7 Tighten six box bolts to 54 72 N m 5 6 7 3 kgf m 40 53 ftelbf 8 Tightenfour cab boltsto 68 92 N m 6 9 9 3 kgf...

Page 1350: ...val referring to lnstallation Note I 4x2 WlTH 14 INCH WHEEL I w 1 6 10N m o 81 6102 0 kgf cm 70 80 in lbf WITH 15 INCH WHEEL 4 0 4 1 6 0 3M 81 102 0 kgf cm 70 80 in4bt 4 0 4 1 6 0 30 44 N m kgf m ft4b...

Page 1351: ...012 Channel bolts Tightening torque 20 30 N m 2 1 3 0 kgfam 15 22 ft lbf 5BUOSX 024 Nuts Tightening torque 40 54 N m 4 1 5 5 kgf m 30 40 ft Ibf 6BUOSX 013 Eyebolt Tightening torque 8 1 0 N m 81 6 1 0...

Page 1352: ...on 1 Remove in the order shown in the figure 2 Install in the reverse order of removal Note The spare tire is designedfor emergency use only Warning Continuoususeof thesparetireonlimitedslip rearaxlee...

Page 1353: ...BODY DIMENSIONS s BODY DIMENSIONS Short Bed DS I I I I I I I I I I II I I I I I I I I I I 1 TOP OF FRONT FENDER BOLT I I I II I I I I I f g I I 1 1 I I I I I II I I I I I I I I1 I I I I mm INCHIIS...

Page 1354: ...s BODY DIMENSIONS Long Bed DRIVER SlDE 1 I I I I i I Top of ront Fender Bon I I I II I I I I T E I I 1 1 1 I I 1 1 11 1 1 1 I SlDE VIEW I I I I I...

Page 1355: ...485 382 10 101 15 W 707 27831 A B C D E F G H I J K L M N 0 P Q I I MSlO91 B Measuring Points 1 23 40 0 9 x 1 57 2 Front fender bolt 3 Bolt 4 Bolt 5 Bolt 6 Nut 7 16 0 63 8 Driver side 44 1 73 Passenge...

Page 1356: ...an assembly 1 Remove seat and track as shown in the figure 2 Repair and replace as necessary 3 Install in the reverse order of removal 4 Torque front seat to floorsupport retaining screws and front se...

Page 1357: ...the figure 2 Repair or replace as necessary 3 Assemble in the reverse order of disassembly 1 Head restraint 2 Pole guide 3 Seat back pad support 4 Seat latch 5 Seat back 6 Seat cushion 7 Adjuster wir...

Page 1358: ...s an assembly 1 Remove seat and track as shown in the figure 2 Repair and replace as necessary 3 Install in the reverse order of removal 4 Torquetrack to floorboltsto 17 23 N m 1 7 2 3 kgf m 13 17 ft...

Page 1359: ...emble in the order shown in the figure 2 Repair or replace as necessary 3 Assemble in the reverse order of disassembly 1 Knucklecover 2 Recliningknuckle 3 Seat back cover 4 Seat back 5 Seat cushion 6...

Page 1360: ...AY POWER BUCKETSEAT Removal1 Installation Note Seat and seat track are removed as an assembly 1 Disconnect the electrical connectors 2 Remove four bolts 3 Remove the seat 4 Install in the reverse orde...

Page 1361: ...assembly DRIVER SIDE SHOWN PASSENGER SIDE SIMILAR MS2002 A 1 Seat garnish 2 Power seat switch 3 Reclining knuckle 4 Knuckle knob 5 Seat cushion 6 Seat back 7 Seat back cover 8 Seat back frame 9 Lumbar...

Page 1362: ...in the order shown in the figure 2 Repair and replace as necessary 3 Install in the reverse order of removal 1 Seat cover and tie strap on seat back frame 3 Lumbar support pad unclip2 pad wires from...

Page 1363: ...val Installation 1 Remove jump seat cover trim and jump seat as shown in figure 2 Repair or replace as necessary 3 Install in the reverse order of removal 4 Torque bolts to 19 26 N m 1 9 2 6 kgf m 14...

Page 1364: ...air or replace as necessary 3 Assemble in the reverse order of disassembly DRIVER SlDE SHOWN I PASSENGER SlDE SIMILAR 1 Rear adjuster covers 2 Outer adjuster cover 3 Inner adjuster cover 4 Return spri...

Page 1365: ...isassemble in the order shown in the figure 2 Repair or replace as necessary 3 Assemble in the reverse order of disassembly DRIVER SIDE S H O W N I PASSENGER SIDE SIMILAR 1 Center armrest 2 Stopper 3...

Page 1366: ...behindthe truck with eye levelat the top of the box have assistant liftwhichever side of the straightedge is necessary to make parallel to the back window of the cab 8 Measurethedistancebetweenthe bot...

Page 1367: ...I D x 060 p p p p p 1 L shim see illustration screwed to No 5 sill 5 shims same as No 4 shims No shims BOX SHIMMING SPECIFICATIONS Location No 4 box bolt rearmost No 5 l l next sill forward it does n...

Page 1368: ...ethe top of the sail plate on the mirror to If If remove the the step sail sail 2 interior plate plateis isdoor against forward trim the ofand the window window mirror channel assembly channel go and...

Page 1369: ...o step 5 Ifthe seal is pinchedltrapped removethat lower A pillar trim to releasethe weatherstrip and rein stall trim 5 Air Leaksfrom Heater or A C System Inspect for air leaks If OK go to step 6 6 DL0...

Page 1370: ...sunshade mounting hole to increase air pressure in the concern area Check for bubbles Note Special attention should be paid to the roof A pillar seam nearthetop of the A pil lar If no bubbles are pre...

Page 1371: ...r of the glass WARNING Excessive force may damage the rear window or cause injury 2 Perform step 9 1 If window is still leaking and vehicle IS equipped with a solid rear window remove and reseal rear...

Page 1372: ...nched portion of the door seal from the trim removal of the trim may be necessary 2 Poor Body Sealant at A Pillar Body Seam and Poor Seal at Front Windshield 1 Remove the upper A pillar trim 2 Verify...

Page 1373: ...If the waterleak occurs between the wind shield urethane and the sheet metal THIS SHOULD NOT BE CONSIDERED A POOR WINDSHIELD SEAL If the waterleak occurs betweeri the windshield and the urethane remov...

Page 1374: ...m at the top of the inner fender apron 2 If no waterleak can be found go to step 5 3 If a waterleak occurs removethe boltsfrom the fender Carefully move fender back 3 4 from the inner fender Note Do n...

Page 1375: ...directiontowards the rightside of the vehicle the location of the PCM box Note A leak in this area may also cause driveabil ity concerns during wet conditions 2 Checkfor leakagearoundthe floor at the...

Page 1376: ...m Place soapy water onthe exterior of theA pillarandon the cabside bodyseam Usean airhosethrough the sunshade mounting hole to increase air pressure in the concern area Check for bubbles Note Special...

Page 1377: ...a Some moisture at the bottom of the cab quarter is normalif vehicle isdriv nthr ugh standing water or in heavy rain a If moisture is not present go to step 2 a If moisture is present inspect the fron...

Page 1378: ...nd reseal quarter window If moisture is present and vehicle is equipped with a flip cab quarter window go on to step 2 2 2 Verify that the quarter window is centered in the sheet metal opening Adjust...

Page 1379: ...hnician 2 Perform step 3 1 If window is still leaking and vehicle is equipped with a solid rear window remove and reseal rear window If moisture is presentand vehicle is equipped with a slide rear win...

Page 1380: ...arter seam Apply water to the concernarea Inspectthe bottomof reartrim panel and inspectthe bottomof the cab quarter for mois ture If moisture is not present go to step 2 If moisture is present inspec...

Page 1381: ...SPECIAL TOOLS ENGINE ST 2 MANUAL TRANSMISSION ST 3 AUTOMATIC TRANSMISSION ST 4 CHASSIS ST 6 CHECKER AND OTHER EQUIPMENT ST 9 4BUSTX 001...

Page 1382: ...OI 008 Fan clutch nut wrench 1 49 UNOl 064 I 1 TOOL NUMBER DESCRIPTION Rear main seal installer ILLUSTRATION 1 49 UNOl 067 Camshaft belt tensioner tool 49 UNOl 068 Front cover al gnment tool 2 3L cran...

Page 1383: ...134 Valve seal replacer 49 UNOl 073 ILLUSTRATION D 49 UNOI 135 Valve spring compressor 1 49 UNO1 136 I f I Rear main oil seal pilot and seal replacer 49 UNOl 006 Fuel line coupling tool TOOL NUMBER DE...

Page 1384: ...rvo rod selecting 1 tool 49 UNOl 017 Lip seal protector 49 UNOl 018 Lip seal protector outer seal 1 49 UNOl 020 I I Front pump seal staking tool Axle bearing1 seal plate TOOL NUMBER DESCRIPTION TOOL N...

Page 1385: ...tch outer seal sizer 49 UNOl 139 Valve body alignment pin 0 235 diameter 49 UNOl 140 Valve body alignment pin 0 248 diameter 49 UNOl 141 Direct clutch outer seal sizer 49 UNOl 142 Oil pump gear O ring...

Page 1386: ...replacer Driver handle 1 dia 7 long Output shaft bearing replacer Bearing installer set Step plate adapter I Oil seal installer TOOL NUMBER DESCRIPTION Axle tube bearing replacer ILLUSTRATION Differe...

Page 1387: ...g puller Hex locknut wrench 49 UNOI 038 1 49 UNOl 030 Dummy bearings Spindle bearing replacer 49 UNOl 031 49 UNOl 040 Hub seal replacer Differential bearing replacer 49 UNOl 032 49 UNOl 042 bearing o...

Page 1388: ...LUSTRATION 1 Gauge block TOOL NUMBER DESCRIPTION Bearing remover ILLUSTRATION Gauge block I Collar A 49 UN27 004 Collar B Pinion 1 p t gauge Impact slide hammer 49 UN11 101 Adapter Axle bearing1 seal...

Page 1389: ...HECKER AND OTHER EQUIPMENT 49 UNOl 071 Transrn ss on TOOL NUMBER ILLUSTRATION 49 UNOl 131 Air Bag Simulator 49 UNOl 132 4R44E Cable Overlay 49 UNOl 154 Digital TR Sensor Adapter Cable and Overlay 49 T...

Page 1390: ...TD 12 F1 IF2 IF3 FUEL AND EMISSION CONTROL SYSTEMS 2 3L 3 OL 4 OL TD I3 G ENGINE ELECTRICAL SYSTEM TD 14 H CLUTCH TD 14 J1 MANUAL TRANSMISSION TD 15 J2 TRANSFER CASE TD 16 K AUTOMATIC TRANSMISSION TD...

Page 1391: ...9 170 1185 120172 1199 121 174 904 92131 1144 116166 Minimum kPa Kgficm2 psi 848 87 123 1406 142204 1055 108153 1420 144206 i1062 108154 1213 123176 1241 126180 125411271827 1268 128184 1282 130186 12...

Page 1392: ...meter mm in Guide inner diameter IN EX 0 025 0 068 0 0010 0 0027 Valve stem to guide clearance 0 038 0 081 0 0015 0 0032 A 43 7644 37 I 723 1 7471 37 84 38 35 11 49 1 511 EX 1 Maximum I 0 139 0 0055 V...

Page 1393: ...re taper mm in 0 25 0 01 Cylinder bore out of round mrn in 0 13 0 005j _ _ L Piston Standard Maximum 1 Piston diameter mm in 1 Red Piston to cylinderclearance rnm in 0 254 0 508 0 01O 0 020 Piston rin...

Page 1394: ...earing oil clearance Standard 7 Mainjournal diameter rnrn in rnrn in Allowable I Available undersizedbearing rnm in 0 050 0 002 I Standard size 0 050 0 002 undersize Crankpin bearincj I 56 02 56 00 2...

Page 1395: ...0 254 0 01 1 Valve and valve guide Valve face runout k 0 05 0 0021 Valve face angle Valve stem diameter mm in Guide inner diameter Standard 1 7 96 7 94 l0 3134 0 3126 I Standard 1 7 94 7 92 0 3129 0...

Page 1396: ...00 3 504 I piston I I Red 88 962 88 978 13 5024 3 5031 I I Blue 88 988 89 004 3 5035 3 5041 I mm in I Yellow 89 014 89 030 3 5045 3 5051 1 I Piston to cylinderclearance mm in Standard 0 030 0 050 0 0...

Page 1397: ...63 9 78 2 5180 2 51 88 0 050 0 002 undersize 63 934 63 953 2 517 2 51 78 I vailablle undersized bearing mm in 1 0 025 0 001 0 050 0 002 1 Main journal out of round mm in i 0 008 0 0003 1 Crankpin bea...

Page 1398: ...ide I Valve head diameter mm in I IN 1 EX Valve face angle Valve stem diameter mm k I Guide inner diameter Valve stem to guide clearance mm in 1 Standard I 8 02 8 04 0 3159 0 31 671 I 1 0 20 0 0081ove...

Page 1399: ...mm in 1 0 07 0 003 per 152 4 6 0 Cyllnder bore d ameter 1 Standard slze mm ln 100 40 1 00 43 I3 9527 3 9543 Cyl nder bore out of round mm ln 0 381 0 584 0 015 0 023 End gap 1 Measured In cylinder 0 3...

Page 1400: ...er mm in1 56 9798 57 0026 12 2433 2 2441 I I Main iournal out of round mm in1 I 0 0152 0 00061 I 1 Crank in diameter mm in I 53 9800 54 0004 2 1252 2 1 260 I I Crank in out of round mm in I 0 0152 0 0...

Page 1401: ...n mm in 18 5 23 3 kgf 21 22 kgf i8 4 10 6 Ibf i 9 1 10 1 lbfJ Oil filter Viscosity number 35 3 1 3911 30 0 32 3 kgf 113 614 7 IbR SAE 1OW 30 SAE 5W 30 MTDl009 C El E2 E3 COOLING SYSTEM 2 3L I 3 OL I4...

Page 1402: ...i Type Variable reluctance type Mass air flow sensor r p Type 1 Heat resistor Engine coolant temperature sensor I 20 C 68 F L p 37 3 Resistance kQ 40 C I 04 Fj 4 16 15 80 C I7 6 3 84 Intake air tempe...

Page 1403: ...System I Spark advance 1 Electronic spark advance ESA 1 10 2 Not adjustable compartment F r na order 1 34 2 1 4 2 5 3 6 2 Automatic tensioner indicator must fall between 4 and 25 markings on belt ten...

Page 1404: ...ining ring I I Thrust clearance End play Thrust washer and counter reverse gear mm in Standard 1 0 00 0 05 0 00 0 0020 Standard Thrust washers 3rdl4th clutch hub end play mm in 7 45 0 293 7 65 0 301 7...

Page 1405: ...TD TECHNICAL DATA J2 TRANSFER CASE...

Page 1406: ...clearance mm in 1 1 3 2 0 0 051 0 0791 9 3 10 8 8 1 Retaining ring Thickness mm in 1 37 0 05393 1 73 0 0681 2 08 0 0819 2 44 0 0961 Diameter mm in I 130 1 l5 122 Forward clutch Retaming ring to pressu...

Page 1407: ...5BUTDX 015 Idle EPC 141 211 1 1 4 2 1 20 30 261 331 2 6 3 3 37 47 148 218 152 2 21 31 141 211 1 4 2 1 20 30 324 394 I3 2 3 9 46 56 218 288 WOT Stall 1 Line 540 753 5 4 7 5 77 107 815 1021 8 2 10 2 11...

Page 1408: ...Inches Diameter Oil Pump Thrust Washer Selection mm 130 1 130 1 Inches 0 0539 0 0681 mm A 1 1 37 Inches 5 122 5 122 5 122 5 122 B 0 0819 I 130 1 0 0961 130 1 1 73 C D 2 08 2 44 Thrust washer identifi...

Page 1409: ...3 20 27 0 3 3 4 71 82 44 51 Part throttle Wide open throttle 1 analal pull down I I 2 1 49 56 30 35 ___I I I A MK1478 B 5BUtdX 016 Axle ratio 3 73 1 kmlh mph I Closed throttle 24 32 15 20 15 22 9 14 I...

Page 1410: ...1 Shift h h p r n l h rnph Minimum throttle Closed throttle 23 30 14 19 I 15 22 9 14 Part throttle 21 30 I3 19 13 22 8 14 Wide open throttle I Manual pull down Throttle Postion L Range Closed throttl...

Page 1411: ...2 I 23 32 14 20 17 25 10 16 15 24 9 15 I Throttle Postion Range Manualpull down I 1 L PROPELLER SHAFT Shift Item Front propeller shaft Rear propeller shaft Runout llrnlt rnrn n 0 8G 035 MTD1017 A 4BUT...

Page 1412: ...TECHNICAL DATA TD Rear propeller shaft angles...

Page 1413: ...ort I _ Opposed tapered roller bearings J _1 API Service GL 5 SAE 90 SAE 80W 1 42 3 2 51 1 1 65 I3 5 3 03 Grade Bearing play Minimum mm in I 0 127 0 005 axial direction p Maximum mm in I 0 762 0 030 1...

Page 1414: ...reload when readjusting 45 N cm I 1 14 in lbsl 290 grams 10 2 ounces Maximum clearance between adjusting screw head and sector shaft 1 0 75L 1 6 pt I Oil pump minimumflow Literslminute76 C 170 F I I 3...

Page 1415: ...diaphragm I mm in mm in 228 6 9 254 1O Q WHEELS AND TIRES SIZE OFFSET AND PITCH CIRCLE DIAMETER Mechanicaltwo rear wheel control Pedal Rear wheel anti lock brake system Parking brake Rear wheel hydrau...

Page 1416: ...eel 15 x 7 0 J P215 75R15SL O tion Aluminum alloy 15 x 7 0 J P235 75R15SL 4x4 Regular Cab 2892 114 4x4 Regular Cab 2892 114 4x4 Cab Plus 3175 1251 Steel Standard Steel Steel Standard Steel Option Alum...

Page 1417: ...70R14SL 4x2 Caster spllt _ _ 1___ Rear suspension 4x4 4x2 4x4 Front wheel al gnment Unladen cond t on I Suspension 1 Rigid axle I Total toe in mm In L 0 82 3 2 0 030 0 1251 degree 06 25 Camber angle 2...

Page 1418: ...TECHNICAL DATA STANDARD BOLT AND NUT TIGHTENING TORQUE 4T 8T Diameter 1 Pitch 1 mm in mm in r n 1 kgf rn ft bf r n k g f i 7 f t l b f 6T h l b...

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