Isuzu 2000 Trooper UX Скачать руководство пользователя страница 1 | Manualshive

Страница: 1 / 2150

background image

WORKSHOP MANUAL

TROOPER

(UX)

FOREWORD

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

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

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

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

This manual applies to 2000 models.

SECTION

TABLE OF CONTENTS

GENERAL INFORMATION

0A

General Information

0B

Maintenance and Lubrication

HEATING, VENTILATION AND AIR CONDITIONING

1A

HVAC Systems

STEERING

2A

Power Assisted System

SUSPENSION

3C

Front Suspension

3D

Rear Suspension

3E

Wheel and Tire System

DRIVELINE/AXLE

4A1

Differential (Front)

4A2

Differential (Rear)

4B1

Driveline Control System (SHIFT ON THE FLY)

4B2

Driveline Control System (TOD)

4C

Drive Shaft System

4D1

Transfer Case (Standard Type)

4D2

Transfer Case (TOD)

BRAKE

5A

Brake Control System

5B

Anti-Lock Brake System

5C

Power-Assisted Brake System

5D

Parking Brake System

ENGINE

6A

Engine Mechanical

6B

Engine Cooling

6C

Engine Fuel

6D1

Engine Electrical

6D2

Ignition System

6D3

Starting and Charging System

6E

Driveability and Emissions

6F

Engine Exhaust

6G

Engine Lubrication

6H

Engine Speed Control System

6J

Induction

TRANSMISSION

7A

Automatic Transmission

7A1

Transmission Control System

7B

Manual Transmission

7C

Clutch

BODY AND ACCESSORIES

8A

Lighting System

8B

Wiper/Washer System

8C

Entertainment

8D

Wiring System

8E

Meter and Gauge

8F

Body Structure

8G

Seats

8H

Security and Locks

8I

Sun Roof/Convertible Top

8J

Exterior/Interior Trim

RESTRAINTS

9A

Seat Belt System

9J

Supplemental Restraint System (SRS)

9J1

Restraint Control System

CONTROL SYSTEM

10A

Cruise Control System

1
2
3
...
»

Содержание 2000 Trooper UX

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

Страница 2: ...f the parts cannot be maintained if these parts are reused 8 To facilitate proper and smooth reassembly operation keep disassembled parts neatly in groups Keeping fixing bolts and nuts separate is ver...

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

Страница 4: ...ication Vehicle Identification Number VIN This is the legal identification of the vehicle it is located on the left bottom of the windshield It can be easily seen through the windshield from outside t...

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

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

Страница 7: ...g Label Plate Location The stamping label and plate locations are indicated by arrows in the illustration below NOTE A VIN plate locations for production B Stamping locations for service parts Engine...

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

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

Страница 10: ...nti theft component NOTE Be sure to pull off the masking tape after paint work has been completed Do not attempt to remove this label for any reason 901RW083 Precautions in pulling off the masking tap...

Страница 11: ...nts Raising the vehicle from any other point may result in serious damage D When jacking or lifting a vehicle at the frame side rail or other prescribed lift points be certain that lift pads do not co...

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

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

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

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

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

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

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

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

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

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

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

Страница 23: ...eller shaft flange to pinion bolts for proper torque to 63 N m 46 lb ft for front and rear propeller shaft Auto Cruise Control Inspection Check to see if the clearance between cruise link and accelera...

Страница 24: ...oper viscosity Clutch system a Pivot points Engine oil b Clutch fork joint Chassis grease c Master cylinder DOT 3 hydraulic brake fluid Hood latch assembly a Pivots and spring anchor Engine oil b Rele...

Страница 25: ...art Lubricants should be carefully selected according to the lubrication chart It is also important to select viscosity of lubricants according to the ambient temperature by referring to the following...

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

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

Страница 28: ...nd moisture from the bolts and the female threaded surfaces of the parts to be joined The surfaces must be perfectly dry 2 Apply LOCTITE to the bolts F00RW014 3 Tighten the bolts to the specified torq...

Страница 29: ...118 N m 87 lb ft Tire inflation pressure Front 210 kPa 30 psi Tire inflation pressure Rear 240 kPa 35 psi Unless otherwise specified on tire information label on the vehicle Approximate Capacities Ite...

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

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

Страница 32: ...htening sequence and specifications Following these instructions can help you avoid damage to parts and systems Heating and Ventilation System General Description Heater When the engine is warming up...

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

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

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

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

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

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

Страница 39: ...fan switch Blower motor speed is controlled in stages by the resistor by operating the switch from LOW to HIGH For the inspection of the relays switches and units in each table refer to INDIVIDUAL INS...

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

Страница 41: ...K Short circuit between chassis side connector terminal No B5 2 and No B3 2 No B3 3 and No I18 6 No B3 6 and No I18 3 No B3 4 and No I18 5 or No B3 1 and No I18 2 Replace control lever assembly Indivi...

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

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

Страница 44: ...ove driver lap vent nozzle 13 Remove center ventilation lower duct Installation To install follow the removal steps in the reverse order noting the following points 1 When handling the PCM and the con...

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

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

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

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

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

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

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

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

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

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

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

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

Страница 57: ...Turn the control knob to the right DEFROST position 2 Connect the control cable at the DEFROST position of the mode control link of the heater unit and secure it with the clip 2 Check the control cabl...

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

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

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

Страница 61: ...lass installed on top of the receiver drier shows the state of the refrigerant A receiver drier may fail due to a restriction inside the body of the unit A restriction at the inlet to the receiver dri...

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

Страница 63: ...le or no cooling 2 Discharge line A restriction in the discharge line generally will cause the discharge line to leak 3 Liquid line A liquid line restriction will be evidenced by low discharge and suc...

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

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

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

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

Страница 68: ...ant Discharge and recover the refrigerant Recharge to the specified amount Leaks in the refrigerant system Check the refrigerant system for leaks and repair as necessary Discharge and recover the refr...

Страница 69: ...l lever set to MAX COLD D Air source selector lever at CIRC D Open the engine hood D Close all the doors Normal Pressure D At ambient temperature approx 25 30 C 77 86 F D At low pressure side approx 1...

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

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

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

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

Страница 74: ...Go to Step 7 6 Check to see if continuity between compressor side connector terminal No E3 1 and the magnetic clutch side connector terminal Is there a continuity Magnetic clutch defective Compressor...

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

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

Страница 77: ...gs immediately Never remove the caps or plugs until the lines or parts are reconnected or installed D When disconnecting or reconnecting the lines use two wrenches to support the line fitting to preve...

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

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

Страница 80: ...ld come in contact with any part of the body flush the exposed area with cold water and immediately seek medical help D If it is necessary to transport or carry any container of HFC 134a in a vehicle...

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

Страница 82: ...ssure does not change D Check for refrigerant leaks by using a HFC 134a leak detector D If a leak occurs recover the refrigerant Repair the leak and start all over again from the first step of evacuat...

Страница 83: ...they settle down to the pressure guidelines shown below D The ambient temperature should be between 25 30 C 77 86 F D The pressure guideline for the high pressure side is approximately 1372 9 1863 3...

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

Страница 85: ...ed to prevent foreign matter from being mixed into the line 6 Remove compressor Installation 1 Install compressor D Tighten the compressor fixing bolts to the specified torque Torque 19 N m 14 lb ft 2...

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

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

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

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

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

Страница 91: ...rator core 874RY00006 10 Remove expansion valve D Tear off the insulator carefully D Remove the sensor fixing clip D Use a back up wrench when disconnecting all refrigerant pipes Installation To insta...

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

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

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

Страница 95: ...nsion 235 mm 9 3 in 225 3 mm 8 9 in 60 mm 2 4 in EXPANSION VALVE Type Internal pressure equalizer type THERMOSTAT SWITCH Type Electronic thermostat OFF Below 3 5 0 5 C 38 3 0 9 F ON Above 5 0 0 5 C 41...

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

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

Страница 98: ...below are based on bench overhaul with the compressor removed from the vehicle except as noted They have been prepared in order of accessibility of the components When a compressor is removed from th...

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

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

Страница 101: ...n line contact with the inner race of the bearing loosen the J 8433 1 center forcing screw and realign the installer and pilot so that the J 33017 installer will properly clear the front head 901RW005...

Страница 102: ...33026 to full fixture thickness 901RW007 4 Turn the center forcing screw of J 8433 1 puller crossbar to force the clutch coil onto the front head Be sure clutch coil and J 33024 installer stay in line...

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

Страница 104: ...ide of the lip seal must be engaged with knurled tangs of installer so that flared out side of lip seal is facing and installed towards the compressor Install seal protector J 34614 in the seal lip an...

Страница 105: ...refrigerant may have leaked out Conduct a leak tests on the connections of each system and if necessary repair or replace faulty parts 5 Check the compressor oil contamination Refer to Contamination o...

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

Страница 107: ...ng of less than 620 kPa 90 psi would indicate one or more suction and or discharge valves leaking an internal leak or an inoperative valve and the refrigerant must be recovered and the compressor disa...

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

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

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

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

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

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

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

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

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

Страница 117: ...re Using the intake switch allows you to select a desired intake port manually in the manual operation FRESH and RECIRC modes alone are available Pressing the DEF defrost mode switch selects the FRESH...

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

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

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

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

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

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

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

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

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

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

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

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

Страница 130: ...s D The detected temperature of thermo unit is 136 F or less D The temperature setting signal and the total signal by each sensor meet the condition of heating When the detected temperature by the coo...

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

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

Страница 133: ...ntinuity between the harness side connector terminal No I33 16 and the ground Go to Step 7 Go to Step 6 6 Repair an open circuit between terminal No I33 16 and the ground No B 2 Is the action complete...

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

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

Страница 136: ...sor 3 Set the temperature setting lever on the automatic heater air conditioner panel to the center position 77 F 4 Set the fan switch on the same panel to the Auto position Is the action complete Go...

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

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

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

Страница 140: ...CONDITIONING HVAC 1A 111 Inspection By Failed Location Inspection of the Sensors When the self diagnosis function has determined that trouble is present on the sensors check them according to the foll...

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

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

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

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

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

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

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

Страница 148: ...sing the temperature control lever select FC for the temperature Is the battery voltage applied on a regular interval basis between the harness side connector terminal No I45 6 and No I45 8 Go to Step...

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

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

Страница 151: ...F mode switch Is the battery voltage provided on a regular interval between the chassis side connector terminal No B69 5 and No B69 1 Go to Step 5 Go to Step 4 4 Replace the auto air conditioner contr...

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

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

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

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

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

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

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

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

Страница 160: ...0 21 Dose the thermo relay ON when connecting ground to the harness connector terminal No H16 6 Go to Step 23 Go to Step 22 22 Failure on the auto air conditioner control unit Is the action complete V...

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

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

Страница 163: ...For handling of these relays refer to Heater Relay in this section 901RY00041 Triple Pressure Switch V6 A T 1 Disconnect the connector and check for continuity between pressure switch side connector t...

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

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

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

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

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

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

Страница 170: ...nerally such coatings adversely affect the fastener torque and the joint clamping force and may damage the fastener When you install fasteners use the correct tightening sequence and specifications Fo...

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

Страница 172: ...center track rod by ball studs transfers the steering force to the wheels The outer track rods are adjustable and are used for toe in adjustments The center track rod is supported by the pitman arm an...

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

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

Страница 175: ...hten mounting bolt Faulty steering gear Check and adjust steering gear Wandering or Poor Steering Stability Mismatched or unevenly worn tires Replace tire or inflate tires to proper pressure Loose ste...

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

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

Страница 178: ...ace turn signal switch Loose or misplaced springs Replace turn signal switch Foreign parts and or material Repair turn signal switch Loose turn signal switch mounting screws Tighten mounting screws Tu...

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

Страница 180: ...vel is low add power steering fluid as specified in General Information to the proper level and install the receiver cap 4 When checking the fluid level after the steering system has been serviced air...

Страница 181: ...e running Free play 0 30 mm 0 1 18 in 2 Also check the steering wheel for play and looseness in the mount by moving it back and forth and sideways When test driving check for hard steering steering sh...

Страница 182: ...ould be slightly ahead toward the front of the vehicle of the upper ball joint center line Toe in This illustration is viewed from the top of the vehicle 480RS003 Toe in is the measured amount the fro...

Страница 183: ...trim height 1 by means of the adjusting bolt on the height control arms CAUTION When adjusting front end alignment be sure to begin with trim height first as it may change other adjusted alignments 4...

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

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

Страница 186: ...ED SYSTEM Main Data and Specifications General Specification Caster 2 10 45 Camber 0 30 King pin inclination 12 30 30 Toe in 0 2 mm 0 0 08 in Max steering angle inside 34 0 to 2 outside 32 Torque Spec...

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

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

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

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

Страница 191: ...in the outlet side 440RS002 5 Remove lock nut D Remove the adjusting screw lock nut and turn the adjusting screw counter clockwise to remove the preload between the sector gear and the rack piston 6...

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

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

Страница 194: ...0kg cm with the sector shaft adjusting screw D Measure the worm shaft preload with the worm gear turned 450 both to the right and to the left The worm gear preload in these positions should be 0 4 0 6...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 213: ...wheels are pointing straight ahead 2 Turn the ignition switch to LOCK 3 Disconnect the battery terminal cable and wait at least 5 minutes 4 Disconnect the yellow 2 way SRS connector located under the...

Страница 214: ...e with a new one Installation 1 Install inflator module CAUTION D Never use the air bag assembly from another vehicle Use only the air bag assembly for UX D The driver s air bag assembly Inflator modu...

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

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

Страница 217: ...r 1999 model has different characteristic to the parts for 1998 model When replace the driver s air bag assembly confirm the parts number and use only the parts for 1999 model The driver s air bag ass...

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

Страница 219: ...E WITH THE URETHANE SIDE UP THIS IS NECESSARY BECAUSE A FREE SPACE IS PROVIDED TO ALLOW THE AIR CUSHION TO EXPAND IN THE UNLIKELY EVENT OF ACCIDENTAL DEPLOYMENT OTHERWISE PERSONAL INJURY MAY RESULT 82...

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

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

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

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

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

Страница 225: ...has different characteristic to the parts for 1998 model When replace the driver s air bag assembly confirm the parts number and use only the parts for 1999 model The driver s air bag assembly for 19...

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

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

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

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

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

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

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

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

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

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

Страница 236: ...ber Replace shock absorber Hard driving Replace tire Overloaded vehicle Replace tire and reduce load Tires not rotated periodically Replace or rotate tire Worn or loose road wheel bearings Replace whe...

Страница 237: ...ts Poor Steering Wheel Returnability Bind in steering linkage ball joints Replace ball joints Bind in upper or lower ball joints Replace ball joints Bind in steering column and shaft Repair or replace...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 252: ...ower control arm 11 Remove the shock absorber lower end from the lower control arm 12 Remove the lower ball joint from the lower control arm 13 Remove front bolt 14 Remove rear bolt 15 Remove lower co...

Страница 253: ...036 3 Install lower ball joint bolt 4 Install torsion bar arm bolt 5 Install lower control arm 6 Install rear bolt 7 Install front bolt 8 Install lower ball joint and tighten it to the specified torqu...

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

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

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

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

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

Страница 259: ...ith stabilizer bar Torsion bar spring Length 1217 mm 47 9 in Diameter 26 6 mm 1 05 in Front shock absorber Type Hydraulic double acting telescopic Piston diameter 30 0 mm 1 18 in Stroke 130 0 mm 5 12...

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

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

Страница 262: ...and stabilizer In this suspension the links are specially arranged to enable the rear axle to move freely thereby expanding suspension stroke reducing friction and improving lateral rigidity and roll...

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

Страница 264: ...of the coil spring to the coil spring seat and mount the coil spring on the rear axle case 460RS003 3 Install the insulator on the coil spring Jack up the axle case gently with the top of the coil spr...

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

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

Страница 267: ...sure that the trailing link is in its correct position NOTE When mounting trailing link be sure not to use grease on bushings or any other nearby part 460RS008 2 Install bolt and nut Tighten the bolt...

Страница 268: ...eed sensor cable from the center link 2 Remove the speed sensor cable bracket from the frame 3 Remove bolt and nut 4 Remove center link Inspection and Repair Make necessary correction or parts replace...

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

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

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

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

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

Страница 274: ...ing Free length 402mm 15 83in Spring diameter 12 7mm 0 5in Coil diameter inner 105mm 4 13in Effective No of turns 5 32 Total No of turns 6 82 Shock absorber Type Hydraulic double acting telescopic Pis...

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

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

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

Страница 278: ...affect bearing life brake performance speedometer odometer calibration vehicle ground clearance and tire clearance to the body and chassis All model are equipped with metric sized tubeless steel belte...

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

Страница 280: ...6 High tire temperatures 7 Reduced handling 8 Reduced fuel economy Unequal pressure on same axle can cause 1 Uneven braking 2 Steering lead 3 Reduced handling 4 Swerve on acceleration Radial Tire Wad...

Страница 281: ...3 Wheel alignment The way in which a tire is built can produce lead in a car An example of this is placement of the belt Off center belts on radial tires can cause the tire to develop a side force wh...

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

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

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

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

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

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

Страница 288: ...nd Specifications General Specifications Wheels Size 16 x 7JJ Offset 38 0 mm 1 50 in P C D wheel studs 139 7 mm 5 50 in Standard tire Size P245 70R16 Pressure Front 210 kPa 30 psi Pressure Rear 240 kP...

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

Страница 290: ...ign Noises in Front Axle Insufficient gear oil Replenish the gear oil Wrong or poor grade gear oil Replace the gear oil Drive pinion to ring gear backlash incorrect Adjust the backlash Worn or chipped...

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

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

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

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

Страница 295: ...haft assembly LH 412RS006 20 Remove front drive shaft assembly RH Installation 1 Install front drive shaft assembly RH and lay the assembly on the lower arm 2 Install front axle case assembly and fron...

Страница 296: ...the connector 8 Install the actuator side of vacuum hose NOTE Be careful not to permit the entry of dust into the hose 9 Connect breather hose and install the hose clip 10 Install protector and tight...

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

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

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

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

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

Страница 302: ...ion mounting distance A plus number indi cates the need for a greater mounting distance which can be achieved by decreasing the shim thickness A minus number indicates the need for a smaller mounting...

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

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

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

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

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

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

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

Страница 310: ...tial cage carrier 5 Thrust washer 6 Oil seal Ring gear replacement 1 The ring gear should always be replaced with the drive pinion as a set 2 Clean the ring gear threaded holes to remove the locking a...

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

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

Страница 313: ...e Hypoid Gear ratio to 1 4 300 Differential type Two pinion Oil capacity liter US qt 1 4 1 5 Differential 0 12 0 13 Actuator Housing Shift on the fly Type of lubricant 75W 90 GL 5 Multi grade type Ref...

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

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

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

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

Страница 318: ...4A2 2 DIFFERENTIAL REAR In case of Work Shop Manual A type Refer to 98 UBS Work Shop Manual B type Described in 00UBS Work Shop Manual 425RY00018...

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

Страница 320: ...wheel bearing noise to diminish Front wheel bearings may be checked for noise by jacking up the wheels and spinning them or by shaking the wheels to determine if bearings are loose 6 Rear suspension r...

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

Страница 322: ...bearing holder fixing nut and take out the axle shaft assembly be sure not to damage the oil seal by the spline of the shaft Refer to Axle Shaft in this section 22 Remove differential assembly refer...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 339: ...and Adjustment 1 Apply a thin coat of Prussian blue or equivalent to the faces of the 7 8 teeth of the ring gear Check the impression of contact on the ring gear teeth and make necessary adjustment as...

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

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

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

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

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

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

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

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

Страница 348: ...2 0 008in Also the total size difference of the friction disc plate and spring disc should be 0 05mm 0 02in or less Thickness 1 65 1 75 1 85mm 0 065 0 069 0 073 in Backlash adjustment of the side gear...

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

Страница 350: ...4A2 34 DIFFERENTIAL REAR 28 Check the operation D Measure the starting torque using the side gear holder Starting torque 29 45 N m 3 0 4 6 kg m 22 33Ib ft 425RW065 Legend 1 Side Gear Holder J 44450...

Страница 351: ...1 in Gear type Hypoid Gear ratio to 1 4 300 Differential type Two pinion Lubricant Grade GL 5 Standard differential GL 5 LSD Limited slip differential Locking Differential Lubricant 80W90 GL 5 USE Lim...

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

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

Страница 354: ...LLUSTRATION TOOL NO TOOL NAME J 42829 Installer Side bearing J 39602 Remover Outer bearing J 39858 Clutch pack unloading tool kit Includes J 34174 1 J 34174 2 Screw cap and Cap J 22342 15 Forcing scre...

Страница 355: ...ERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING REFER TO THE SRS SERVICE INFORMATION FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT PERSONAL INJURY OR OTHERWI...

Страница 356: ...controls below operations Shifting between 4H and 4L must be performed by transfer control lever on the floor 1 Shifting the transfer front output gear Connecting to and disconnecting from front prope...

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

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

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

Страница 360: ...2WD Open On 4WD On Open 4WD Close 4WD Close Blink 2Hz Operating On Open 4WD Close 2WD Open Off Close 2WD Open 4WD Close Blink 4Hz Stop operating On Open 2WD Open 2WD Open Off Close 4WD Close 4WD Clos...

Страница 361: ...eels is not completed because the indicator s blinking changes to 4Hz when the shifting transfer gear is impossible And removal of rotation or phase difference make connecting the front wheels possibl...

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

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

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

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

Страница 366: ...Solution 1 again After that disassemble the transfer case assembly for check and repair or replace If incident is not improved after above mentioned actions were taken replace the 4WD control unit 2...

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

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

Страница 369: ...r actuator Trace this chart from the start after or replace Go to Step 3 3 Pull out the hoses from vacuum actuator and operate 4WD switch Is there negative pressure on either of hoses Go to Step 4 Fau...

Страница 370: ...igh to 4L or vice versa Faults on the harness wiring of motor actuator Trace this chart from the start after repair or replace Faults on the motor actuator Trace this chart from the start after replac...

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

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

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

Страница 374: ...during inspection 6 Pull out Hose D in above illustration 7 Plug Hose E in above illustration 8 Make sure that Hose D in above illustration is under atmospheric pressure 9 Pull out Hose E and plug Hos...

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

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

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

Страница 378: ...le assembly Refer to Interior Trim in Body and Accessories section 2 Remove nut 3 Remove 4WD control unit 4 Disconnect harness connector 1 412RW045 Legend 1 Harness Connector Installation 1 Connect ha...

Страница 379: ...COMPONENTS OR THE SRS WIRING WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING REFER TO THE SRS SERVICE INFORMATION FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE A...

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

Страница 381: ...e initial torque distribution using these data and the information from the speed sensors In case of small circle turning in the parking lot for example the control unit minimizes the clutch pressing...

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

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

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

Страница 385: ...INE CONTROL SYSTEM TOD Check Lamp Inform the following items D Bulb check D Fail fail alarm D Trouble code 821RW078 TOD ECU This control unit is mounted to the front right hand seat via a special brac...

Страница 386: ...ing Transition of Transfer Lever When the transfer lever is shifted and the signals from the AXLE switch do not comply with the signal conditions of the 4H and 4L switch the transfer lever position si...

Страница 387: ...5 Bulb Check When the starter switch is turned on the TOD indicator lamps go on as shown below NOTE Once the starter switch is turned on all the TOD indicator lamps are lit for two seconds even if the...

Страница 388: ...ed while the self diagnostic code is being displayed the self diagnostic connector is short circuited to GND you can simply check the ABS IN and BRAKE ON signals as shown in the figures below C07RW017...

Страница 389: ...by the procedures Diagnosis from Trouble Codes and Trouble Diagnosis Depending on The Status of TOD Indicator The troubles that can be recognized as abnormal phenomena of the vehicle by the driver are...

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

Страница 391: ...amage and connect the terminals securely 3 It is likely that wires in the harness are falsely broken Therefore in examination of failed harness circuit shake the harness for check to such extent that...

Страница 392: ...ndition and give appropriate maintenance according to the diagnostic procedure Even if the phenomena are not observed try to reproduce the abnormal state reported by the customer to the possible exten...

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

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

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

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

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

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

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

Страница 400: ...Not used 6 IND b Display Front B 7 N C Not used 8 IND Rr Display Rear E 9 N C Not used 10 N C Not used 11 SOL EMC 12 Ref Speed Reference 13 COM Speed Return 14 VIG Ignition 15 TPS TPS PWM 16 TECH 2 T...

Страница 401: ...Frt Sig Front Speed Signal 33 ABS IN ABS In 34 VIG Ignition 35 N C Not used 36 4WD OUT 4WD Signal Output 37 BRAKE Brake Switch Input 38 N C Not used 39 N C Not used 40 LIGHTING SW Lighting Switch Inp...

Страница 402: ...ONTENTS 1 Ref Rer Rear speed sensor reference output 2 Ref Frt Front speed sensor reference output 3 SW GND SW GND 4 4H SW 4H SW plus terminal 5 Rer Rear speed sensor plus 6 Frt Front speed sensor plu...

Страница 403: ...4 5 V 18 IND c ON STOP DCV 18 46 8 0 14 5 V 20 CHECK LAMP ON STOP DCV 20 46 8 0 14 5 V 33 ABS IN ON STOP DCV 33 46 11 5 14 5 V 12 Ref ON STOP DCV 12 46 5 9 V Connect ECU 32 Ft ON STOP DCV 32 46 0 7 6...

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

Страница 405: ...2 to the DLC cable 4 3 Connect the DLC cable to the Tech 2 4 4 Mark sure the vehicle ignition is off 5 Connect the Tech 2 SAE 16 19 adapter to the vehicle DLC connector 821RW021 6 The vehicle ignitio...

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

Страница 407: ...iring abnormality in input 7 23 ECU CPU abnormality 1 24 Rear speed sensor Input abnormality open sig or com 5 26 EMC Shorted GND 10 27 Rear speed sensor Input abnormality 4 28 ADC AXLE SW Output abno...

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

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

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

Страница 411: ...low Trouble code Phenomenon Standard 3 16 The front speed sensor no pulse Hi level 4 5 6 0 V Lo level 0 7 2 0 V Frequency F 766 Hz at 30 mile h NOTE Find the trouble in which the pulse corresponding t...

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

Страница 413: ...low Trouble code Phenomenon Standard 4 27 The front speed sensor no pulse Hi level 4 5 6 0 V Lo level 0 7 2 0 V Frequency F 766 Hz at 30 mile h NOTE Find the trouble in which the pulse corresponding t...

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

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

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

Страница 417: ...6 13 The reference is short circuited to GND Reference 5 V 15 The reference Vb is short circuited If the reference wire 15 is short circuited to GND the speed signal is not generated If the wire is s...

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

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

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

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

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

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

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

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

Страница 426: ...enon Standard 11 28 The shift on the fly system front hub works incorrectly NOTE The shift on the fly system is not changed between 2WD and 4WD modes normally CAUTION If code 32 or 33 is also observed...

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

Страница 428: ...non Standard 12 32 The on off signal ADC line of the shift on the fly system front hub is broken or the line is short circuited to the battery NOTE The on off signal line of the shift on the fly syste...

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

Страница 430: ...ine is short circuited to GND NOTE D The on off signal line of the shift on the fly system is short circuited to GND D The system enters into the fail safe mode because of fusing or system protection...

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

Страница 432: ...r Functional check with TOD indicator light is conducted prior to check on Charts A H D After the starter is switched on check and see if the status has become as tabulated below C07RY00019 D If the s...

Страница 433: ...tion of circuit The circuit informs the indicator of the working condition of the ECU Fail condition All the TOD indicator lamps and CHECK lamp are lit and go off momentarily at an inter val of about...

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

Страница 435: ...WD switch circuit wires are broken or short circuited to the GND Function of circuit Fail condition Even after the transfer position is select from TOD to 2H the indicator lamp status is not changed I...

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

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

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

Страница 439: ...short circuited Function of circuit Fail condition When the 4WD Auto Switch is 4WD mode When the lever is shifted from 4L to TOD the 4L mode remains on the indicator and the TOD mode is displayed with...

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

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

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

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

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

Страница 445: ...oken or the battery is short circuited Function of circuit Fail condition The TOD mode is displayed in the neutral position between high and 4L When the lever is shifted to the 4L position the TOD mod...

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

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

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

Страница 449: ...uity established between terminals B 48 22 and B 48 24 Go to Step 8 Go to Step 10 8 When the transfer lever is shifted to the 4L position is the continuity established between terminals B 48 22 and B...

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

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

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

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

Страница 454: ...switch circuit is short circuited to GND Function of circuit Fail condition Even after the 4WD Auto Switch is select to the 2WD position the 2WD mode is not en abled The transition status is not remov...

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

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

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

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

Страница 459: ...t Function of circuit Reads in the status of lighting switch reducing the indicator at night Fail condition Even if the lighting switch is pressed on and off brightness does not change Indicator lamp...

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

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

Страница 462: ...ner braking is observed Function of circuit Fail condition When the vehicle is subject to full steering in the TOD mode the drive resistance gets large or the judder occurs Otherwise the above phenome...

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

Страница 464: ...and start the creep run Does the voltage between terminals 11 and 22 range between 0 1 and 1 0V Go to Step 15 Go to Step 13 15 1 Select the 4WD Auto Switch to the 2WD position 2 Jack up the right fron...

Страница 465: ...Chart 2 The 4WD mode is not active Function of circuit Fail condition The rear wheels spin in the TOD mode so the driving torque is not transmitted to the front wheels The indicator lamps will not sh...

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

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

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

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

Страница 470: ...p 3 Repair the battery system Go to Step 4 3 1 Select the 4WD SW to the 2WD position 2 The voltage between terminals 36 and 46 range between 7 5 and 16V 0 12 seconds make a cycle Does the voltage with...

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

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

Страница 473: ...s in Front Axle Insufficient gear oil Replenish the gear oil Wrong or poor grade gear oil Replace the gear oil Drive pinion to ring gear backlash incorrect Adjust the backlash Worn or chipped ring gea...

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

Страница 475: ...ing 10 Use a brass bar to remove the outer bearing outer race 1 oil seal inner bearing and inner bearing outer race 2 from the hub 411RS002 11 Remove bolt 12 If necessary replace the wheel pin in the...

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

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

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

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

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

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

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

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

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

Страница 485: ...in the nut just enough to obtain alignment D Screw is to be fastened tightly so its head may come lower than the surface of the washer 411RS012 10 Apply adhesive LOCTITE 515 or equivalent to both joi...

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

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

Страница 488: ...eload Check Check the hub bearing preload at the wheel pin New bearing and new oil seal 19 6 24 5 N 4 4 5 5 lb Used bearing and new oil seal 11 8 17 7 N 2 6 4 0 lb 411RS001 Inspection Of Shift On The...

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

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

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

Страница 492: ...to the shaft for smooth installation then install bellows 8 Install band Note the setting direction After installation check that the bellows is free from distortion 412RS017 9 Install another bellow...

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

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

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

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

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

Страница 498: ...nnect the shift position switch and make sure of function with a vacuum of 400 mmHg applied to Ports A and B in accordance with the table below State Port A Port B Function C 400 mmHg A P E D A P 400...

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

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

Страница 501: ...il capacity 1 4 liter 1 48 US qt Differential 0 12 liter 0 13 US qt Actuator Housing Shift on the fly Type of lubricant GL 5 Multi grade type Refer to chart in General Information Axle shaft type Cons...

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

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

Страница 504: ...ropeller Shaft with TOD 5 Coupling 6 LJ Constant Velocity Joint 7 BJ Constant Velocity Joint Removal 1 Jack up the vehicle and support it on the chassis stands 2 Gear shift lever should be placed in n...

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

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

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

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

Страница 509: ...shaft as an assembly Play in Constant Velocity Joint Fix the shaft in a vise throrgh pieces of wood and try to move the joint vertically right and left and back and forth to make sure of smooth motion...

Страница 510: ...0 15 mm 0 006 in 401RW046 2 Set a dial gage at right angle near the inner circumference and check the run out of the flange Limit 0 15 mm 0 006 in 401RW045 3 If vibration is felt during the 4H AUTO dr...

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

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

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

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

Страница 515: ...t from the connecting surface of flange coupling on each end of propeller shaft Clean so that no foreign matter will be caught in between 2 Align the mark which is applied at removal Install rear prop...

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

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

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

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

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

Страница 521: ...ngine 6VE1 3 5 L Transmission M T A T A T with TOD Construction Hollow steel tube with yoke and spider type universal joints Outside diameter 68 9 mm 2 71 in 68 9 mm 2 71 in 68 9 mm 2 71 in Length 109...

Страница 522: ...TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING REFER TO THE SRS SERVICE...

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

Страница 524: ...peration when the vehicle is driven on improved roads where four wheel drive is not required In addition the transfer case provides an additional gear reduction when placed in low range which is usefu...

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

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

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

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

Страница 529: ...E 17430 or its equivalent to the transfer rear case fitting faces 220RS017 3 Perform the following steps before fitting the transfer rear case 1 Shift the high low shift to the 4H side 2 Turn the sele...

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

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

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

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

Страница 534: ...Install ball bearing use the ball bearing installer J 37223 to install the ball bearing 226RS065 8 Install the rear output shaft assembly to the transfer rear case 9 Install bearing snap ring NOTE The...

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

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

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

Страница 538: ...D1 17 16 Engage the 2WD 4WD sleeve with the 4WD side and install the spring pin 262RW022 17 Install spring pin and bridge 18 Install detent ball spring and plug and tighten the plug to the specified t...

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

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

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

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

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

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

Страница 545: ...an the specified limit the detent spring must be replaced Detent spring free length Detent ball Compressed height 18 7 mm 0 736 in Standard 68 6 88 2 N 15 4 19 8 lb Interlock pin Compressed height 11...

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

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

Страница 548: ...facing the front output gear side 20 Use a bench press to slowly force the clutch sleeve and hub assembly together with the stopper plate into place 21 Align the inserts with the block ring insert gr...

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

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

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

Страница 552: ...een low and high Control method Remote control with the gear shift lever on the floor for gear shifting between low and high Electric control with the button switch on the instrument panel for gear sh...

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

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

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

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

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

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

Страница 559: ...ight cross member hanger and shift the proper shaft to the end 260RW006 12 Unplug the 4WD switch connector from the transmission harness 13 Unplug the transfer connector from the top of the transfer c...

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

Страница 561: ...ple the rear propeller shaft from the transfer case 2 Using the flange holder J 8614 11 remove the end nut 3 Using the universal puller remove the rear companion flange and O ring 4 Remove the oil sea...

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

Страница 563: ...he battery cable 2 Move the passenger seat forward and remove the second seat foot rest 1 3 Unplug the connector from the ECU 2 4 Remove the set bolts and detach the ECU 2 from the bracket F07RW021 In...

Страница 564: ...us terminal 810RW002 4H and 4L switches Check whether the 4H switch terminals 4 and 7 and 4L switch terminals 12 and 3 work as specified in the table below If yes the continuity is established on thes...

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

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

Страница 567: ...ng to the dent of the companion flange and then attach the washer 8 Use the flange holder J 8614 11 to tighten the flange nuts to transfer case 9 Tighten the flange nut with the specified torque Torqu...

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

Страница 569: ...ack with a precision screwdriver or other appropriate tool starting from the small lock of the plate NOTE Pay attention not to damage the stopper plate during the work 261RW042 5 Using a terminal pull...

Страница 570: ...y oil to the circumference of the new oil seal and fill the lip with grease Besco L2 or equivalent 3 Using the oil seal installer J 42804 attach the oil seal to the transfer cover assembly 261RW035 4...

Страница 571: ...rminal in the central connector NOTE Pay attention not to damage other terminals 9 Install speed gear and tone wheel 10 Mount the ball bearing 2 flat as shown in the figure 261RW009 11 Using snap ring...

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

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

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

Страница 575: ...l lock hub 7 Remove lock up fork 8 Remove the spring retainer from the connection between rail shaft and lock up fork 9 Remove lock up sleeve 261RW018 10 Remove thrust washer 11 Remove the magnet from...

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

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

Страница 578: ...3 Using snap ring pliers attach the snap ring 261RW021 14 Remove the reduction lever assembly 15 Remove the snap ring 16 Remove the shifter lever shaft 17 Remove the front output shaft 266RW012 18 Rem...

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

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

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

Страница 582: ...n the gear spline Remove minor flaws or scratches with oil stone If excessive wear or damage is observed replace the part D If excessive wear or damage is observed on the sprocket inside sliding surfa...

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

Страница 584: ...imit 130 N 13 3 kg 261RW041 Oil Pump D Remove foreign materials from the strainer If the strainer is damaged replace it D If the area into which the shaft is inserted is excessively worn or damaged re...

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

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

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

Страница 588: ...l bearing to the input shaft so that the snap ring will be attached to the input shaft 265RW003 12 Attach the snap ring to the input shaft 13 Attach the snap ring to the transfer case 14 Using the sna...

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

Страница 590: ...ssembly to the shifter lever shaft and fix the assembly with the snap ring 261RW021 4 Mount the cam to the cam pilot 5 Attach the washer to the cam pilot block and fix the washer with the snap ring 26...

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

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

Страница 593: ...and fork together to the output shaft and shifter roll assembly 7 Mount the spring retainer to the lock up fork 261RW018 8 Install mechanical lock hub 9 Apply ATF to the chain 10 Engage the chain to...

Страница 594: ...e Spring 6 Cam Pulley 7 Cam Ball 8 Cam and Coil Housing 9 Thrust Bearing Reassembly 1 Mount the clutch pack assembly to which the multi plate disk clutch is already installed to the output shaft NOTE...

Страница 595: ...TOD 4 Using snap ring pliers attach the snap ring 266RW009 5 Install the wave spring 6 Install the cam pulley 7 Place a ball on each groove of the cam pulley 266RW013 8 Install the cam and coil housi...

Страница 596: ...nge reduction mechanisn 2H Rear wheel drive TOD Electronically controlled torque split four wheel drive 4L Low speed mechanical lock up four wheel drive Control system Floor direct control Gear ratio...

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

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

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

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

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

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

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

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

Страница 605: ...mponent are properly mounted Was this step finished Finished Go to Step 5 2 Inspection of Front Axle Switch Step Action Yes No 1 Turn the key switch on and shift to 4WD position by pressing the 4WD sw...

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

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

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

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

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

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

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

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

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

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

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

Страница 617: ...1 ABS Works Frequently But Vehicle Does Not Decelerate Step Action Yes No 1 1 Turn key off 2 G Sensor connector and EHCU connector disconnected Is there continuity between EHCU terminals 26 and 8 Go t...

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

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

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

Страница 621: ...FL Decompression Solenoid Valve Shorted or disconnected coil wiring B 11 43 FR Holding Solenoid Valve Shorted or disconnected coil wiring B 12 44 FR Decompression Solenoid Valve Shorted or disconnecte...

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

Страница 623: ...ng warning light D Double digit display D First normal DTC 12 is displayed three times and then any other DTCs are displayed three times If no other DTCs have been stored the display of DTC 12 will be...

Страница 624: ...codes can be stored D If the ABS should turn OFF due to an intermittent defect the system will be restored at the next key cycle if the initial check finds no abnormality when IGN is switched from OF...

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

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

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

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

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

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

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

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

Страница 633: ...nd EHCU Fault found Repair and perform system self check No fault found Replace EHCU Go to Step 3 Go to Step 2 2 Measure the RR speed sensor resistance at the sensor connector Is the sensor resistance...

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

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

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

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

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

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

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

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

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

Страница 643: ...ther than the L and R Go to Step 7 Go to Step 6 4 Is Off Road Switch Transmission Input Active when the shift lever is in 1 2 and R Go to Step 5 Go to Step 6 5 Is Off Road Switch Transmission Input In...

Страница 644: ...KE CONTROL SYSTEM Special Tools ILLUSTRATION TOOL NO TOOL NAME J 35616 Connector test adapter kit J 39200 High impedance multimeter 7000086 ISU Tech 2 Set 1 PCMCIA Card 2 SAE 16 19 Adapter 3 DLC Cable...

Страница 645: ...THE SRS WIRING WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING REFER TO THE SRS SERVICE INFORMATION FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYM...

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

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

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

Страница 649: ...nd disc Installation 1 Install speed sensor and take care not to hit the speed sensor pole piece during installation 2 Install speed sensor fixing bolt and tighten the fixing bolt to the specified tor...

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

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

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

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

Страница 654: ...W001 Rear Disc Brake A05RW002 Hydraulic pressure created by applying the brake pedal is converted by the caliper to a stopping force This force acts equally against the piston and the bottom of the ca...

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

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

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

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

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

Страница 660: ...e repeated 28 After the bleeding operation is completed on the each individual wheel check the level of the brake fluid in the reservoir and replenish up to the MAX level as necessary 29 Attach the re...

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

Страница 662: ...ign material off the hose fittings at both ends 4 Disconnect brake pipe 5 Remove clip 6 Remove brake pipe 7 Remove bolt 8 Remove hose Installation To install follow the removal steps in the reverse or...

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

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

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

Страница 666: ...at is moves away from the brake pedal d Loosen the lock nut on the push rod e Adjust the brake pedal to the specified height by rotating the push rod in the appropriate direction f Tighten the lock nu...

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

Страница 668: ...0RW004 Installation 1 Install switch and adjust the stoplight switch to the specified clearance between the switch housing and the brake pedal by rotating the switch housing Clearance 1 0 0 2 mm 0 0 0...

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

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

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

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

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

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

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

Страница 676: ...ure to measure push rod and adjust if required 2 Remove retainer from vacuum booster front shell using a small screwdriver Then gently draw plate and seal assembly out of the shell inside 331RS003 3 S...

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

Страница 678: ...eal Assembly 11 Master Cylinder Removal 1 Remove master cylinder refer to Master Cylinder in this section 2 Remove vacuum booster refer to Vacuum Booster in this section 3 Remove yoke clevis 4 Remove...

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

Страница 680: ...al Specifications Vacuum booster diaphragm diameter Front 205 mm 8 07 in Vacuum booster diaphragm diameter Rear 230 mm 9 06 in Push rod stroke More than 32 0 mm 1 26 in Plunger diameter 10 25 mm 0 40...

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

Страница 682: ...orn to about the thickness of the pad base the pad should be removed for further measurements The pad should be replaced anytime the pad thickness 1 is worn to within 1 00 mm 0 039 in of the pad itsel...

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

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

Страница 685: ...measurement of thickness of the rotor at four or more points around the circumference of the rotor All measurements must be made 29 mm 1 14 in from the edge of the rotor The rotor thickness must not...

Страница 686: ...refinishing replace any rotor that does not meet the minimum thickness of 24 97 mm 0 983 in Do not use a brake rotor that will not meet the specification Minimum wear dimension 24 60 mm 0 969 in Refin...

Страница 687: ...mbly 5 Clip 6 Support Bracket with Pad Assembly 7 Pad Assembly Removal 1 Raise the vehicle and support with suitable safety stands 2 Wheel and tire assembly refer to Wheels and Tires System in Section...

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

Страница 689: ...ll brake flexible hose always use new gaskets and be sure to put the hooked edge of the flexible hose end into the anti rotation cavity then tighten the I bolt 10 to the specified torque Torque 35 N m...

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

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

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

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

Страница 694: ...ad is worn to about the thickness of the pad base the pad should be removed for further measurements The pad should be replaced anytime the pad thickness 1 is worn to within 1 0 mm 0 039 in of the pad...

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

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

Страница 697: ...asurement of thickness of the rotor at four or more points around the circumference of the rotor All measurements must be made 22 mm 0 87 in from the edge of the rotor The rotor thickness must not var...

Страница 698: ...he specification Minimum wear dimension 16 6 mm 0 654 in Refinish dimension 16 97 mm 0 668 in 420RW002 Rear Drum In Disc Inside Diameter Check Check the rear drum inside diameter by measuring at more...

Страница 699: ...3E 3 Remove the bolt and gaskets then disconnect the flexible hose from the caliper and after disconnecting the flexible hose 1 cap or tape the openings to prevent entry of foreign material 306RW008...

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

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

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

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

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

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

Страница 706: ...quire a replacement after removal ISUZU will also call out the fasteners that require thread lockers or thread sealant UNLESS OTHERWISE SPECIFIED do not use supplemental coatings Paints greases or oth...

Страница 707: ...he secondary shoe against the brake drum using the lever shoe joint B as a fulcrum and pushes the strut in the direction C The strut in turn presses the primary shoe against the brake drum Counter for...

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

Страница 709: ...cable 2 Install parking brake lever and apply grease BESCO L 2 or equivalent to front cable contact point 3 Reconnect switch connector 4 Install bolts and tighten the parking brake lever fixing bolt t...

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

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

Страница 712: ...h until the rotor does not turn b Turn the adjusting screw in the opposite direction upward until the rotor can be turned lightly Standard number of notches to turn upward 7 or 8 Turn the rotor in ord...

Страница 713: ...cations Rear parking brake Type Duo servo Lining Dimension 121 2 cm 18 79 in Adjusting Method Manual adjusting Rotor Drum Inside Diameter 210 mm 8 27 in Parking Brake Lever Stroke 6 7 notches When pul...

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

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

Страница 716: ...cause extensive damage when the engine is started Cylinder Block The cylinder block is made of aluminum die cast casting for 75 V type six cylinders It has a rear plate integrated structure and employ...

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

Страница 718: ...pression Test Procedure 1 Start and run the engine until the engine reaches normal operating temperature 2 Turn the engine off 3 Remove all the spark plugs 4 Remove ignition coil fuse 15A and disable...

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

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

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

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

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

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

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

Страница 726: ...eized Replace valve and valve guide Valve spring broken or weakened Replace Valve seat off positioned Correct Camshaft worn out Replace Crankshaft noise Crankshaft end play excessive noise occurs when...

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

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

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

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

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

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

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

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

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

Страница 736: ...ustration 060RY00111 Legend 1 Green Connector 2 Blue Connector 3 Identification Mark 6VE1 Engine Only 10 Install air cleaner duct assembly 013RY00001 Legend 1 Positive Crankcase Ventilation Hose Conne...

Страница 737: ...compressor bracket and loosen two bolts for A C compressor then move A C compressor to front side 8 Remove exhaust manifold eight fixing nuts and remove exhaust manifold from the engine Installation 1...

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

Страница 739: ...Driver Belt 5 Remove cooling fan assembly four fixing nuts then the cooling fan assembly 6 Remove crankshaft pulley assembly using J 8614 01 crankshaft holder hold crankshaft pulley then remove center...

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

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

Страница 742: ...aligning the timing marks use a wrench to turn the camshaft drive gear pulley then set the timing mark between timing belt and camshaft drive gear pulley Secure the belt with a double clip NOTE It is...

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

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

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

Страница 746: ...o dots for left bank and exhaust camshaft one dot for right bank two dots for left bank to timing mark on camshaft drive gear one dot 014RW020 Legend 1 Intake Camshaft Timing Gear for Right Bank 2 Int...

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

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

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

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

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

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

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

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

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

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

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

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

Страница 759: ...18 Disconnect generator harness connector from generator 19 Disconnect coolant reserve tank hose from radiator 20 Remove radiator upper and lower hoses 21 Remove upper fan shroud 22 Remove cooling fa...

Страница 760: ...ansmission assembly Refer to Transmission section in this manual 4 Reconnect two heater hoses to engine 5 Install flywheel dust covers 6 Install exhaust pipe and temporally tighten two each bank rear...

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

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

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

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

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

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

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

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

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

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

Страница 771: ...built on the cylinder block give a few turns to the camshaft by means of timing pulley tightening bolt and measure valve clearance when the nose of cam is just opposite to maximum cam lift 1 as shown...

Страница 772: ...L Replacement of Shim Let the cam push down the edge of tappet by using J 42689 valve clearance adjusting tool and push out the shim with a flat blade screw driver as shown in illustrations below 014R...

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

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

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

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

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

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

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

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

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

Страница 782: ...stalling new crankshaft bearings or replacing bearings refer to the selection table below Select and install the new crankshaft bearings paying close attention to the cylinder block journal hole 1 Dia...

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

Страница 784: ...retainer If the seal was removed from retainer for replacement apply engine oil to the oil seal lip and install the oil seal using J 39201 oil seal installer 015RW001 015RS017 3 Flywheel 9 1 Thorough...

Страница 785: ...front of the engine D Match the numbered caps with the numbers on the connecting rods Align the punched marks on the connecting rods and caps D Apply engine oil to the threads and seating faces of the...

Страница 786: ...urfaces The surfaces must be perfectly dry 2 Apply a correct width bead of sealant TB 1207C or its equivalent to the contact surfaces of the oil pan There must be no gaps in the bead 3 The crankcase a...

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

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

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

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

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

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

Страница 793: ...rings must be set with the T or T2 mark facing up Marked T No 1 Compression ring Marked T2 No 2 Compression ring D After installation apply engine oil to the entire circumference of the piston rings...

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

Страница 795: ...ul not to allow any material to accidentally drop into the upper surface of the cylinder block Be very careful not to scratch the upper surface of the cylinder block 2 The cylinder block must be regro...

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

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

Страница 798: ...il pan 1 Completely remove all residual sealant lubricant and moisture from the sealing surfaces The surfaces must be perfectly dry 2 Apply a correct width bead of sealant TB 1207C or its equivalent t...

Страница 799: ...rive Cylinder liner type Casted in cylinder drive Total piston displacement 3494 cc Cylinder bore x stroke 93 4mm x 85 0mm 3 677 in x 3 346 in Compression ratio 9 1 1 Compression pressure at 300rpm 14...

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

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

Страница 802: ...6A 89 ENGINE MECHANICAL Crankshaft main bearing Flywheel Crankcase Oil pan Timing belt tensioner Timing pulley Timing belt cover Oil pump Oil gallery Oil strainer and Water pump E06RW002...

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

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

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

Страница 806: ...OL NO TOOL NAME J 24239 1 Cylinder head bolt wrench J 42899 Replacer Valve guide 1 2 J 42687 Installer Valve guide 1 J 37985 1 Remover Valve guide 2 J 42689 Adjusting Tool Valve clearance J 42686 Leve...

Страница 807: ...AR THE SRS COMPONENTS OR THE SRS WIRING WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING REFER TO THE SRS SERVICE INFORMATION FAILURE TO FOLLOW WARNINGS COULD RESULT IN...

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

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

Страница 810: ...ifreeze solution at a mixing ratio lower than 20 so that the inside of the engine may not be corroded 2 If antifreeze solution is used at a mixing ratio higher than 60 the specific heat of the coolant...

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

Страница 812: ...of the reserve tank with soap and water Flush it well with clean water then drain it Install the reserve tank and hoses 4 Refill the cooling system with the EC using a solution that is at least 50 pe...

Страница 813: ...damage is found during inspection Should any of the following problems occur the entire water pump assembly must be replaced D Crack in the water pump body D EC leakage from the seal unit D Play or a...

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

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

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

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

Страница 818: ...cooling fan assembly and tighten bolts nuts to the specified torque Torque 22 N m 16 lb ft for fan pulley and fan bracket Torque 10 N m 88 5 lb in for fan and clutch assembly NOTE Fan belts for 6VE1...

Страница 819: ...t Radiator front area 0 302m 0 028ft Radiator dry weight 39N 8 8lb 44N 9 9lb Radiator cap valve opening pressure 93 3 122 7kpa 13 5 17 8psi Engine coolant capacity 2 5lit 2 6U S q t 2 4lit 16 3U S q t...

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

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

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

Страница 823: ...into the engine The changing voltage is transformed into an electric signal and provided to the ECM With receipt of the signals sent from the MAP sensor Intake Air Temperature sensor and others the E...

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

Страница 825: ...ned thoroughly Fuel Pump Flow Test If reduction of fuel supply is suspected perform the following checks 1 Make sure that there is fuel in the tank 2 With the engine running check the fuel feed pipe a...

Страница 826: ...uel filler cap 3 Drain fuel Tighten drain plug to the specified torque after draining fuel Torque 20 N m 14 lb ft M8 4 Remove fuel tank assembly 1 Refer to Fuel Tank Removal in this section 5 Remove f...

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

Страница 828: ...nnect battery ground cable Fuel Tube Quick Connect Fittings Precautions D Lighting of Fires Prohibited D Keep flames away from your work area to prevent the inflammable from catching fire D Disconnect...

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

Страница 830: ...ust from the pipe and make sure that the end including spool is free from defects such as scratch rust and dent which may cause poor sealability If defective replace with a new pipe D After cleaning t...

Страница 831: ...ground cable 2 Loosen fuel filler cap 3 Drain fuel Tighten drain plug to the specified torque after draining fuel Torque 20 N m 14 lb ft M8 4 Wiring connector D Disconnect wiring connector 1 from the...

Страница 832: ...lve 2 Pressure Valve Inspection Check the seal ring in the filler cap for presence of any abnormality and for seal condition Replace the filler cap if abnormal CAUTION The fuel filler cap valves have...

Страница 833: ...ery will refuse to accept an extensive charge A conventional battery will accept an excessive charge resulting in gassing and loss of battery fluid 3 The battery is much less vulnerable to self discha...

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

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

Страница 836: ...ns General Specifications Model JIS 95D31R MF 80D26R MF 75D26R MF Voltage V 12 12 12 Cold Cranking Performance Amp 622 582 490 Reserve Capacity Min 159 133 123 Load Test Amp 310 290 245 Fast Charge Ma...

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

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

Страница 839: ...coil assembly for insulation Check terminals for corrosion or damage and replace as necessary Measuring resistance of ignition coil assembly Terminal No Limit 1 to 2 Resistance cannot be 0 ohm short...

Страница 840: ...nt from ignition coil assembly from 1 to 5 Ignition coil assembly 6 is short type So note it when installing ignition coil assembly of 6 060RY00002 Legend 1 Long Type Ignition Coil Assemblies 1 5 2 Sh...

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

Страница 842: ...crankshaft position sensor 3 Remove crankshaft position sensor from cylinder block 012RS008 Installation 1 Install crankshaft position sensor into the cylinder block Before installation apply small am...

Страница 843: ...ral Specifications Ignition System Ignition Form Electronic Ignition System El system with Crankshaft position Sensor Spark Plug Type K16PR P11 RC10PYP4 PK16PR11 Plug gap 1 0 mm 0 04 in 1 1 mm 0 043 i...

Страница 844: ...VICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING REFER TO THE SRS SERVICE INFORMATION FAILURE TO FOLLOW WARNINGS COU...

Страница 845: ...aft When the starter switch is turned on the contacts of magnetic switch are closed and the armature rotates At the same time the plunger is attracted and the pinion is pushed forward by the shift lev...

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

Страница 847: ...n Starter does not run Charging failure Repair charging system Battery Failure Replace Battery Terminal connection failure Repair or replace terminal connector and or wiring harness Starter switch fai...

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

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

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

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

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

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

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

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

Страница 856: ...r bracket D Gears in reduction gear D Shift lever operating portion D Sliding portion of pinion D Plunger sliding portion of magnetic switch Reassembling Yoke Assembly Before reassembly make sure that...

Страница 857: ...conduct the no load test as follows Rating as short as 30 seconds requires rapid testing Fix the starter on the test bench and wire as shown in illustration When the switch is closed the current flows...

Страница 858: ...umber of teeth of pinion 9 Rotating direction as viewed from pinion Clockwise Weight approx 34 N No load characteristics Voltage Current 11V 90A or less Speed 2700rpm or more Load characteristics Volt...

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

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

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

Страница 862: ...uires repair 3 Reconnect the wiring connector to the generator run the engine at middle speed and turn off all electrical devices other than engine 4 Measure battery voltage If it exceeds 16V repair o...

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

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

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

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

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

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

Страница 869: ...and Specifications General Specifications Parts Number Nippon denso 102211 1740 Model ACJV74 Rated voltage 12 V Rated output 90 A Rotating direction As viewed from pulled Clockwise Pulley effective d...

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

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

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

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

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

Страница 875: ...18 Engine Coolant Temperature Sensor 30 22 Fuel Drain Plug 20 14 Fuel Pressure Regulator Attaching Screw 3 26 Fuel Rail Bolts 25 18 Fuel Tank Undercover Retaining Bolts 36 27 Heated Oxygen Sensor 55 4...

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

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

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

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

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

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

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

Страница 883: ...off General Description and Operation A C Cluch Circuit Opreation F5 Mission Main Case GRN RED 0 0V 0 0V 4L30E T Mission F6 Not Used F7 Tachometer BLK RED 8 8V 10 0V at idle Chassis Electrical F8 Not...

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

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

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

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

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

Страница 889: ...nder 3 GRN B B General Description and Operation Fuel Injector F67 ION Sensing Module YEL 1 555V 1 555V General Description and Operation ION Sensing Module F68 ION Sensing Module RED 1 555V 1 555V Ge...

Страница 890: ...Refer To ENG RUN IGN ON Wire Color PIN Function F77 Mode Switch BLU WHT B B 4L30E T Mission F78 Mode Switch BLU BLK B B 4L30E T Mission F79 Mode Switch BLU YEL B B 4L30E T Mission F80 AP Sensor 2 Sens...

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

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

Страница 893: ...ctrical S28 Injector Cylinder 6 GRN YEL B B General Description and Operation Fuel Injector S29 Winter Switch VIO GRN B B 4L30E T Mission S30 Auto Cruise Main Switch PNK BLK 0 0V 0 0V Chassis Electric...

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

Страница 895: ...tem S46 A T Check Transmission Lamp ORN BLK B B Chassis Electrical M T Up Shift Lamp ORN BLK B B Chassis Electrical S47 Winter Lamp PNK GRN B B 4L30E T Mission S48 EVAP Duty Solenoid Valve RED BLU B 5...

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

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

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

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

Страница 900: ...MAF Sensor Attached to the air filter box 8 Camshaft Position CMP Sensor On the rear right side of the left cylinder head 9 Fuel Pressure Regulator Rear side of the engine 10 ION Sensing module Bolted...

Страница 901: ...er Located along the inside of the right frame rail ahead of the rear axle 6 Vehicle Speed Sensor VSS 2WD Protrudes from the transmission housing just ahead of the propeller shaft 4WD Protrudes from t...

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

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

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

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

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

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

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

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

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

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

Страница 912: ...Frame data will only be stored for an A or B type diagnostic and only if the MIL has been requested 2 Clear DTC s 3 Operate the vehicle within conditions noted in the Fail Records and or Freeze Frame...

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

Страница 914: ...handling of the card 7 The Tech 2 can plot a graph when replaying a snapshot 8 Always return to the Main Menu by pressing the EXIT key several times before shutting down 9 To clear Diagnostic Trouble...

Страница 915: ...L ENGINE DRIVEABILITY AND EMISSIONS Operating Procedure For Example The power up screen is displayed when you power up the tester with the Isuzu systems PCMCIA card Follow the operating procedure belo...

Страница 916: ...this ignition up to DTCs DTC tests which run and pass will cause that DTC number to be removed from Tech 2 screen Fail This Ignition This selection will display all DTCs that have failed during the pr...

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

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

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

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

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

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

Страница 923: ...e 13 Push Open Loop or Closed Loop soft key 060RY00099 14 Control O2 Loop and check data list 15 If data list changes the O2 Loop is normal Instruments Test This test is conducted check Instruments fo...

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

Страница 925: ...or this test Test Procedure 1 Connect Tech 2 to the vehicle DLC 2 Run the Engine at idle 3 Select F3 Miscellaneous Test in the Application Menu 060RY00075 4 Select F5 EGR Control Test in the Miscellan...

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

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

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

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

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

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

Страница 932: ...rim System Monitor Diagnostic Operation This system monitors the averages of short term and long term fuel trim values If these fuel trim values stay at their limits for a calibrated period of time a...

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

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

Страница 935: ...it for an open or short to ground and the DLC ground circuit for an open 4 If a problem is found repair as necessary Was a problem found Go to Step 2 Go to Step 13 13 1 Attempt to reprogram the PCM Re...

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

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

Страница 938: ...jumper between ground and the PNK GRN wire at the thermostat 4 A C ON 5 Blower ON Dose A C request indicate YES on the Tech 2 Go to Step 14 Go to Step 17 14 1 Ignition ON 2 Use a DVM to check voltage...

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

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

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

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

Страница 943: ...r to the Coil Test 0 5 amp position 6 Connect the leads from the J 39200 Digital Voltmeter DVM to the injector tester Refer to the illustrations associated with the test description 7 Set the DVM to t...

Страница 944: ...tage selected in step 1 Repeat until you have a subtracted value for each injector For any injector is the subtracted Value in step 2 greater than the specified value 0 6 V Go to Step 4 Go to Step 7 7...

Страница 945: ...uel injector 8 Subtract the second pressure reading from the first pressure reading for one fuel injector The result is the pressure drop value 9 Obtain a pressure drop value for each fuel injector 10...

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

Страница 947: ...t PCM Inspect the harness connectors for backed out terminals improper mating broken locks improperly formed or damage terminals and a poor terminal to wire connection D Damaged harness Inspect the wi...

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 961: ...ection rubbed through wire insulation or a wire broken inside the insulation Check for the following items D Poor connection or damaged harness Inspect the PCM harness and connectors for improper mati...

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

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

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

Страница 965: ...hefuse Is the action complete Verify repair 17 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to ON Vehicle Service in Power Control Module and Sensors for procedures And also...

Страница 966: ...rubbed through wire insulation or a wire broken inside the insulation Check for the following items D Poor connection or damaged harness Inspect the PCM harness and connectors for improper mating bro...

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

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

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

Страница 970: ...ture with intake air temperature on a completely cool engine Engine coolant temperature should be within 10 C of intake air temperature If not replace the ECT sensor Test Description Number s below re...

Страница 971: ...sensing module 3 With a test light to B probe each of the 6 exposed ION sensing module pins one at a time while the engine is cranked Use the gray narrow Metri Pak flexible female connector from the...

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

Страница 973: ...in connector Is the test light ON Go to Step 26 Go to Step 32 26 1 At the PCM female side of the connector connect a test light between the ignition terminal and one of the injector driver circuits at...

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

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

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

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

Страница 978: ...t the horn relay is functioning 2 Substitute the horn relay for the fuel pump relay 3 Leave the test light connected as in step 12 4 Command the fuel pump ON with the Tech 2 Did the test light illumin...

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

Страница 980: ...ation or a wire broken inside the insulation Check for poor connections or a damaged harness Inspect the PCM harness and connector for improper mating broken locks improperly formed or damaged termina...

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

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

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

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

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

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

Страница 987: ...hose gradually apply pressure with the pliers to pinch the flexible fuel return hose closed CAUTION Do not let the fuel pressure exceed the second specified value Does the fuel pressure indicated by...

Страница 988: ...would be replaced with air and the air fuel mixture would be leaner The powertrain control module PCM would compensate for the lean condition by adding fuel resulting in higher long term fuel trim val...

Страница 989: ...and physically inspect the EGR valve pintle valve passages and adapter for excessive deposits obstructions or any restrictions Does the EGR valve have excessive deposits obstructions or any restricti...

Страница 990: ...rometric pressure allowing the PCM to make adjustments for different altitudes The PCM uses the MAP sensor to diagnose proper operation of the EGR system in addition to other functions Test Descriptio...

Страница 991: ...1 Disconnect the vacuum hose at the MAP sensor and plug the hose 2 Connect a hand vacuum pump to the MAP sensor 3 Start the engine 4 Apply 34 kPa 10 Hg of vacuum and note the voltage change Is the vol...

Страница 992: ...s enabled when the appropriate conditions have been met D The engine run time after start is more than 60 seconds D The engine coolant temperature is above 30 C 86 F D The fuel control system is opera...

Страница 993: ...the Tech 2 4 Apply vacuum to the purge solenoid with the hand vacuum pump 5 Start the engine run at 2500 RPM 6 Using the Tech 2 select Powertrain 3 5 V6 6VE1 F3 Misc Tests F2 EVAP Purge F0 EVAP Purge...

Страница 994: ...alve check Refer to Diagnostic Aids 9 1 Disconnect the solenoid electrical connector 2 Connect a test lamp between the harness terminals Does the test lamp light Go to Step 7 Go to Step 10 10 Probe te...

Страница 995: ...6E 126 TROOPER 6VE1 3 5L ENGINE DRIVEABILITY AND EMISSIONS Upshift Lamp System Check Manual Transmission Only 060RY00127...

Страница 996: ...PCM 2 This checks the upshift lamp circuit up to the PCM connector If the up shift lamp illuminates then the PCM connector is faulty or PCM does not have the ability to ground the circuit Up Shift Lam...

Страница 997: ...it Was a problem found Go to Step 11 Go to Step 12 11 1 Replace the Alarm and Relay Control Unit Or 2 Repair for an open of BLU ORN wiring harness between Alarm and Relay Control Unit and PCM connecto...

Страница 998: ...Sensor Circuit Low Voltage Bank 1 Sensor 1 B Yes No P0132 O2 Sensor Circuit High Voltage Bank 1 Sensor 1 B Yes No P0133 O2 Sensor Circuit Slow Response Bank 1 Sensor 1 B Yes No P0134 O2 Sensor Circuit...

Страница 999: ...nal 58X B Yes No P0341 CMP Sensor Circuit Range Performance C No No P0342 CMP Sensor Circuit No signal C No No P0351 Injection 1 Control Circuit A Yes No P0352 Ignition 2 Control Circuit A Yes No P035...

Страница 1000: ...put Voltage D No No P1111 IAT Circuit Intermittent High Voltage D No No P1112 IAT Circuit Intermittent Low Input Voltage D No No P1114 ECT Circuit Intermittent Low Voltage D No No P1115 ECT Circuit In...

Страница 1001: ...Sensing Module Combustion Quality circuit A Yes No P1340 ION Sensing Module Cylinder Synchronization B Yes No P1404 EGR Range Performance Closed Valve B Yes No P1441 EVAP Control System Comtinuous Ope...

Страница 1002: ...11 5 volts and 16 volts Action Taken When the DTC Sets D The PCM will illuminate the malfunction indicator lamp MIL the first time the fault is detected D The PCM calculates an air flow value based on...

Страница 1003: ...hart may isolate the cause of the fault DTC P0101 MAF System Performance Step Action Value s Yes No 1 Was the On Board Diagnostic OBD System Check performed Go to Step 2 Go to OBD System Check 2 1 Ign...

Страница 1004: ...ng does the Tech 2 display the following value s 4 to 7 g s Go to Step 8 Go toStep 9 8 Observe the Tech 2 value while increasing the engine RPM to its upper limit Does the Tech 2 display the following...

Страница 1005: ...mp MIL the first time the fault is detected D The PCM calculates an air flow value based on idle air control valve position throttle position RPM and barometric pressure D The PCM will store condition...

Страница 1006: ...OFF 2 Review and record Tech 2 Failure Records data 3 Operate the vehicle within Failure Records conditions as noted 4 Using a Tech 2 monitor DTC info for DTC P0102 Does the Tech 2 indicate DTC P0102...

Страница 1007: ...action complete Verify repair Go to Step 13 11 Locate and repair the open in the ground circuit to the MAF sensor Is the action complete Verify repair 12 Locate and repair the open in the ignition fe...

Страница 1008: ...M for more than 10 seconds D System voltage is above 11 5 volts D MAF signal frequency is above 40g s for a total of 50 percent of the last 200 samples monitored A sample is taken every cylinder event...

Страница 1009: ...4 A frequency reading with the MAF sensor connector disconnected indicates an electromagnetic interfernce EMI related fault 8 This vehicle is equipped with a PCM which utilizes an electrically erasab...

Страница 1010: ...es the Tech 2 indicate a MAF Frequency at the specified value 0g s Go to Step 5 Go to Step 6 5 Replace the MAF sensor Is the action complete Verify repair Go to Step 8 6 1 Check the MAF harness for in...

Страница 1011: ...han 4 D No change in brake switch A C clutch TCC or power steering pressure switch status D Above conditions are met for longer than 1 second D Actual MAP value varies more than 10 kPa D The MAP value...

Страница 1012: ...tions D Vacuum hoses disconnected damaged or incorrectly routed D Intake manifold vacuum leaks D Vacuum leaks at throttle body D Vacuum leaks at EGR valve flange and pipes D Crankcase ventilation valv...

Страница 1013: ...s found repair as necessary Did the terminal require replacement Verify repair Go to Step 14 11 1 Check for a poor connection at the MAP sensor 2 If a problem is found repair as necessary Was a proble...

Страница 1014: ...manifold absolute pressure at or below 11 kPa for a total of approximately 10 seconds over a 16 second period D Ignition voltage more than 11 volts Action Taken When the DTC Sets D The PCM will illumi...

Страница 1015: ...ds data 3 Operate the vehicle within Failure Records conditions as noted 4 Using a Tech 2 monitor DTC info for DTC P0107 Does the Tech 2 indicate DTC P0107 failed Go to Step 4 Refer to Diagnostic Aids...

Страница 1016: ...Go to Step 9 9 Check the MAP sensor signal circuit for a poor connection at the PCM and the MAP sensor replace the terminal if necessary Did the terminal require replacement Verify repair Go to Step...

Страница 1017: ...ifold absolute pressure above 80 kPa for a total of approximately 10 seconds over a 16 second period Action Taken When the DTC Sets D The PCM will illuminate the malfunction indicator lamp MIL the fir...

Страница 1018: ...rds conditions as noted 4 Using a Tech 2 monitor DTC info for DTC P0108 Does the Tech 2 indicate DTC P0108 failed this ignition Go to Step 4 Refer to Diagnostic Aids 4 1 Ignition OFF 2 Disconnect the...

Страница 1019: ...s a condition found and corrected Verify repair Go to Step 11 11 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control Module and Sensors f...

Страница 1020: ...luminate the malfunction indicator lamp MIL the first time the fault is detected D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data...

Страница 1021: ...able may be used to test the IAT sensor at various temperatures to evaluate the possibility of a shifted sensor that may be stored above or below a certain temperature If this is the case replace the...

Страница 1022: ...tion Refer to Diagnostic Aids 4 1 Ignition OFF 2 Disconnect the IAT sensor electrical connector 3 Ignition ON 4 Observe the intake air temperature on the Tech 2 Is the intake air temperature below the...

Страница 1023: ...or lamp MIL the first time the fault is detected D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data Conditions for Clearing the MIL...

Страница 1024: ...s No 1 Was the On Board Diagnostic OBD System Check performed Go to Step 2 Go to OBD System Check 2 Ignition ON engine OFF Observe the Intake Air Temp display on the Tech 2 Is the Intake Air Temp belo...

Страница 1025: ...al circuit for an open 3 If the IAT sensor signal circuit is open repair it as necessary Was the IAT signal circuit open Verify repair Go to Step 9 9 Check for a poor sensor ground or IAT signal circu...

Страница 1026: ...e default value is based on start up intake air temperature and running time D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data Con...

Страница 1027: ...le may be used to test the ECT sensor at various temperatures to evaluate the possibility of a shifted sensor that may be shorted above or below a certain temperature If this is the case replace the E...

Страница 1028: ...sconnect the ECT sensor electrical connector 2 Observe the Eng Cool Temp display on the Tech 2 Is the Eng Cool Temp at the specified value 39 C 38 F Go to Step 6 Go to Step 5 5 1 Ignition OFF 2 Discon...

Страница 1029: ...air temperature and running time D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data Conditions for Clearing the MIL DTC D The PCM...

Страница 1030: ...the On Board Diagnostic OBD System Check performed Go to Step 2 Go to OBD System Check 2 1 Ignition ON engine OFF 2 Observe the Eng Cool Temp display on the Tech 2 Is the Eng Cool Temp below the spec...

Страница 1031: ...t as necessary Was the ECT signal circuit open Verify repair Go to Step 9 9 Check for a poor sensor ground or ECT signal circuit terminal connection at the PCM and replace terminal s if necessary Did...

Страница 1032: ...esent D Engine is running D Vehicle speed is greater than 5 mph 8 km h D Intake air temperature is greater than 10 C 14 F 0 C 32 F D Start up engine coolant temperature is between 10 C 14 F and 28 C 8...

Страница 1033: ...ne coolant temperature displayed on a Tech 2 with actual coolant temperature measured with a thermometer may isolate this condition If the displayed engine coolant temperature is not close to the actu...

Страница 1034: ...reading Go to Step 12 Go to Step 8 8 Check for high resistance in wiring related to the ECT sensor Also check for poor connections at the ECT sensor and the PCM Was a problem found Go to Step 10 Go to...

Страница 1035: ...ter the second consecutive trip in which the fault is detected D The PCM will store condition which were present when the DTC was set as Freeze Frame and in the Failure Records data Conditions for Cle...

Страница 1036: ...tors and wiring harnesses related to the sensor A change in the display will indicate the location of the fault If DTC P0128 cannot be duplicated the information included in the Faillure Records data...

Страница 1037: ...record Tech 2 Failure Records 3 Opreate the vehicle within Failure Records conditions as noted 4 Using a Tech 2 monitor DTC info for DTC P0128 Does the Tech 2 indicate DTC P0128 failed this ignition...

Страница 1038: ...k 1 HO2S 1 signal voltage remains below 22 mV during normal closed loop operation for a total of 77 seconds over a 90 second period of time Action Taken When the DTC Sets D The PCM will illuminate the...

Страница 1039: ...mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs This may assist in diagnosing the condition DTC P0131 HO2S Circuit Low Vol...

Страница 1040: ...d 3 Ignition ON Does the Tech 2 indicate Bank 1 HO2S 1 voltage between the specified values 425 475 mV Refer to Diagnostic Aids Go to Step 9 9 Replace the PCM IMPORTANT The replacement PCM must be pro...

Страница 1041: ...r a total of 77 seconds over a 90 second period OR D Bank 1 HO2S 1 signal voltage remains above 500 mV during deceleration fuel cutoff mode operation for 3 seconds Action Taken When the DTC Sets D The...

Страница 1042: ...of the above conditions are present replace the affected HO2S Test Description Number s below refer to the step number s on the Diagnostic Chart 3 DTC P0132 failing during deceleration fuel cutoff mod...

Страница 1043: ...7 1 Disconnect the jumpers to ground from Bank 1 HO2S 1 PCM side connector 2 With the HO2S 1 connector disconnected monitor Bank 1 HO2S 1 voltage Is Bank 1 HO2S 1 voltage between the specified values...

Страница 1044: ...in closed loop D Engine has been running for at least 1 minute D Engine speed is between 1500 RPM and 3000 RPM D Canister purge duty cycle is greater than 2 D Mass air flow is between 9 g second and 4...

Страница 1045: ...f DTC P0133 cannot be duplicated reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs Thi...

Страница 1046: ...tep 17 Go to Step 4 4 Check for leaks at the pipe joints Are the joints leaking Go to Step 5 Go to Step 6 5 Tighten the U bolt nuts at the leaking joints Is the action complete Go to Step 2 6 Check fo...

Страница 1047: ...1 voltage Does the Tech 2 indicate less than 10 mV and immediately return to about 450 mV when the jumper is removed Go to Step 21 Go to Step 22 17 Replace the affected heated oxygen sensors NOTE Bef...

Страница 1048: ...D Oxygen sensor heaters are required by post catalyst monitor sensors to maintain a sufficiently high temperature for accurate exhaust oxygen content readings further from the engine Conditions for Se...

Страница 1049: ...be set occurs This may assist in diagnosing the condition DTC P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1 Step Action Value s Yes No 1 Was the On Board Diagnostic OBD System Check perfor...

Страница 1050: ...engine OFF 2 Disconnect Bank 1 HO2S 1 and jumper the HO2S high and low circuits PCM side to ground 3 Using a Tech 2 monitor Bank 1 HO2S 1 voltage Is Bank 1 HO2S 1 voltage in the specified range 0 10...

Страница 1051: ...e is based on the accumulated amount of air that has passed through the MAF sensor and into the engine more accumulated air flow shorter time to HO2S activity Conditions for Setting the DTC D No relat...

Страница 1052: ...heater ground circuit is faulty 5 Checks the HO2S heater ground circuit 6 Checks or an open or shorted HO2S heater element 10 An open HO2S signal or low circuit can cause the HO2S heater to appear fa...

Страница 1053: ...igh or low circuit terminal connection at the Bank 1 HO2S 1 harness connector and replace terminal s if necessary Did any terminals require replacement Verify repair Go to Step 11 11 1 Ignition OFF 2...

Страница 1054: ...etween 3 and 19 D Bank 1 HO2S 2 signal voltage remains below 22 mV during normal closed loop operation for a total of 106 seconds over a 125 second period of time OR D Bank 1 HO2S 2 signal voltage rem...

Страница 1055: ...ittent condition is indicated Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs This m...

Страница 1056: ...d 3 Ignition ON Does the Tech 2 indicate Bank 1 HO2S 2 voltage near the specified value 425 475 mV Refer to Diagnostic Aids Go to Step 9 9 Replace the PCM IMPORTANT The replacement PCM must be program...

Страница 1057: ...0 F D Throttle angle is between 3 and 19 D Bank 1 HO2S 2 signal voltage remains above 952 mV during normal closed loop operation for a total of 106 seconds over a 125 second period of time OR D Bank 1...

Страница 1058: ...mited within a range between 300 mV to 600 mV check the HO2S signal and wiring and associated terminal connections D If none of the above conditions are present replace the affected HO2S Test Descript...

Страница 1059: ...ied value 10 mV Go to Step 7 Go to Step 8 7 1 Disconnect the jumpers to ground from Bank 1 HO2S 2 PCM side connector 2 With the HO2S 2 connector disconnected monitor BANK 1 HO2S 2 voltage Is the Bank...

Страница 1060: ...will be set Heated oxygen sensors are used to minimize the amount of time required for closed loop fuel control operation and to allow accurate catalyst monitoring The oxygen sensor heater greatly de...

Страница 1061: ...urs This may assist in diagnosing the condition DTC P0140 HO2S Circuit Insufficient Activity BANK 1 SENSOR 2 Step Action Value s Yes No 1 Was the On Board Diagnostic OBD System Check performed Go to S...

Страница 1062: ...N engine OFF 2 Disconnect Bank 1 HO2S 2 and jumper the HO2S high and low circuits PCM side to ground 3 Using a Tech 2 monitor Bank 1 HO2S 2 voltage Is Bank 1 HO2S 2 voltage in the specified range 0 10...

Страница 1063: ...ature is based on the total amount of air that has passed through the MAF sensor and into the engine more total airflow shorter time to HO2S activity Conditions for Setting the DTC D No related DTCs D...

Страница 1064: ...ht should be connected to a good chassis ground in case the HO2S low or HO2S heater ground circuit is faulty 5 This checks the HO2S heater ground circuit 6 This checks for an open or shorted HO2S heat...

Страница 1065: ...2 Disconnect the PCM and check the continuity of the Bank 1 HO2S 2 signal circuit and the Bank 1 HO2S 2 low circuit 3 If the Bank 1 HO2S 2 signal circuit or the HO2S low circuit measures over 5 ohms...

Страница 1066: ...Bank 2 HO2S 1 signal voltage remains below 22 mV during normal closed loop operation for a total of 77 seconds over a 90 second period of time Action Taken When the DTC Sets D The PCM will illuminate...

Страница 1067: ...e mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs This may assist in diagnosing the condition DTC P0151 HO2S Circuit Low V...

Страница 1068: ...3 Ignition ON Does the Tech 2 indicate Bank 2 HO2S 1 voltage near the specified value 425 475 mV Refer to Diagnostic Aids Go to Step 9 9 Replace the PCM IMPORTANT The replacement PCM must be programm...

Страница 1069: ...econds over a 90 second period OR D Bank 2 HO2S 1 signal voltage remains above 500 mV during deceleration fuel cutoff mode operation for up to 3 seconds Action Taken When the DTC Sets D The PCM will i...

Страница 1070: ...D If none of the above conditions are present replace the affected HO2S Test Description Number s below refer to the step number s on the Diagnostic Chart 3 DTC P0152 failing during deceleration fuel...

Страница 1071: ...1 Disconnect the jumpers to ground from Bank 2 HO2S 1 PCM side connector 2 With the HO2S 1 connector disconnected monitor Bank 2 HO2S 1 voltage Is the Bank 2 HO2S 1 voltage between the specified valu...

Страница 1072: ...ng in closed loop D Engine has been running for at least one minute D Canister purge duty cycle is above 2 D Engine speed is between 1500 RPM and 3000 RPM D Mass air flow is between 9 g second and 42...

Страница 1073: ...on of the fault Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs This may assist in d...

Страница 1074: ...o Step 17 Go to Step 4 4 Check for leaks at the pipe joints Are the joints leaking Go to Step 5 Go to Step 6 5 Tighten the U bolt nuts at the leaking joint Is your action complete Go to Step 2 6 Check...

Страница 1075: ...e less than 10 mV and immediately return to about 450 mV when the jumper is removed Go to Step 21 Go to Step 22 17 Replace the affected heated oxygen sensors NOTE Before replacing the sensors the caus...

Страница 1076: ...d Bank 2 HO2S 1 to become active Oxygen sensor heaters are required by post catalyst monitor sensors to maintain a sufficiently high temperature for accurate exhaust oxygen content readings further fr...

Страница 1077: ...icated Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occurs This may assist in diagnosing...

Страница 1078: ...ir open or poor connection as necessary Was a Bank 2 HO2S 1 low circuit problem found and corrected Verify repair Go to Step 9 9 1 Ignition ON engine OFF 2 Disconnect Bank 2 HO2S 1 and jumper the HO2S...

Страница 1079: ...is based on the total amount of air that has passed through the mass air flow MAF sensor and into the engine more total air flow shorter time to HO2S activity Conditions for Setting the DTC D No relat...

Страница 1080: ...should be connected to a good chassis ground in case the HO2S low or HO2S heater ground circuit is faulty 5 Checks the HO2S heater ground circuit 6 Checks for an open or shorted HO2S heater element 1...

Страница 1081: ...erify repair Go to Step 10 10 Check for a poor Bank 2 HO2S 1 signal or low circuit terminal connection at the Bank 2 HO2S 1 harness connector and replace terminal s if necessary Did any terminals requ...

Страница 1082: ...r more active than that produced by the Bank 2 HO2S 2 sensor If the Bank 2 HO2S 2 signal voltage remains excessively low for an extended period of time DTC P0157 will be set Conditions for Setting the...

Страница 1083: ...ontamination D If none of above conditions are present replace the affected HO2S 2 Test Description Number s below refer to the step number s on the Diagnostic Chart 3 DTC P0157 failing during operati...

Страница 1084: ...Is the action complete Verify repair 8 1 Ignition OFF 2 Reconnect the PCM leave HO2S 2 disconnected 3 Ignition ON Does the Tech 2 indicate Bank 2 HO2S 2 voltage near the specified value 425 475 mV Re...

Страница 1085: ...ll be far more active than that produced by the Bank 2 HO2S 2 sensor If the Bank 2 HO2S 2 signal voltage remains excessively high for an extended period of time DTC P0158 will be set Conditions for Se...

Страница 1086: ...operation An HO2S which is faulty and does not allow full voltage swing between the rich and lean thresholds can also cause this condition Operate the vehicle while monitoring the HO2S voltage with a...

Страница 1087: ...gnal circuits PCM side to ground 3 Using a Tech 2 monitor Bank 2 HO2S 2 voltage Is Bank 2 HO2S 2 voltage below the specified value 10 mV Go to Step 7 Go to Step 8 7 1 Disconnect the jumpers to ground...

Страница 1088: ...00 mV and 500 mV for an extended period of time DTC P0160 will be set Heated Oxygen sensors are used to minimize the amount of time required for closed loop fuel control operation and allow accurate c...

Страница 1089: ...n intermittent condition is indicated Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition that caused the DTC to be set occur...

Страница 1090: ...r open or poor connections as necessary Was a Bank 2 HO2S 2 low circuit problem found and corrected Verify repair Go to Step 9 9 1 Ignition ON engine OFF 2 Disconnect Bank 2 HO2S 2 and jumper the HO2S...

Страница 1091: ...perature is based on the total amount of air that has passed through the MAF sensor and into the engine more total air flow shorter time to HO2S activity Conditions for Setting the DTC D No related DT...

Страница 1092: ...ground circuit is faulty 5 This checks the HO2S heater ground circuit 6 This checks for an open or shorted HO2S heater element 11 An open HO2S signal or low circuit can cause the HO2S heater to appear...

Страница 1093: ...it and the Bank 2 HO2S 2 low circuit 3 If the Bank 2 HO2S 2 signal circuit or HO2S low circuit measures over 5 ohms repair the open or poor connection as necessary Was a problem found Verify repair Go...

Страница 1094: ...status of the fuel trim diagnostic Conditions for Setting the DTC D No Tech 2 test is being run D None of the following EGR DTCs HO2S DTCs response transition open low volts no activity MAF DTCs TP s...

Страница 1095: ...harness A change in the display will indicate the location of the fault Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition t...

Страница 1096: ...f a driveability symptom still exists refer to Symptoms section 5 Was DTC P0174 also set Go to Step 6 Go to Step 15 6 Visually and physically inspect the vacuum hoses for disconnections splits kinks i...

Страница 1097: ...in the Fuel System Pressure Test and repair fuel system problem if necessary Did Fuel System Pressure Test isolate a condition requiring repair Verify repair Go to Step 15 15 1 Visually and physically...

Страница 1098: ...ion and 20 The PCM s maximum authority to control short term fuel trim allows a range between 11 and 20 The PCM monitors fuel trim under various engine speed load fuel trim cells before determining th...

Страница 1099: ...ng the condition which caused the other DTC will most likely correct the DTC P0172 P0175 4 If the DTC P0172 test passes while the Failure Records conditions are being duplicated the rich condition is...

Страница 1100: ...l pressure regulator refer to Fuel Metering System Did the fuel pressure regulator require replacement Verify repair Go to Step 12 12 Ignition ON engine OFF monitor the TP1 Angle display on the Tech 2...

Страница 1101: ...es a problem repair as necessary refer to Fuel Metering System Did the Injector Balance Test isolate a problem requiring repair Verify repair Go to Step 20 20 1 Remove and visually physically inspect...

Страница 1102: ...ing the status of the fuel trim diagnostic Conditions for Setting the DTC D No Tech 2 test is being run D None of the following DTCs are set idle system EGR HO2S response transition open low volts no...

Страница 1103: ...harness A change in the display will indicate the location of the fault Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how often the condition t...

Страница 1104: ...result Does the Tech 2 indicate DTC P0174 failed this ignition Go to Step 5 The lean condition is not present If a driveability symptom still exists refer to Symptoms section 5 Was DTC P0171 also set...

Страница 1105: ...T FUEL TRIM value decrease to near the specified value 0 Go to Step 19 Go to Step 14 14 Perform the procedure in the Fuel System Pressure Test and repair fuel system problem if necessary Did the Fuel...

Страница 1106: ...rs fuel trim under various engine speed load fuel trim cells before determining the status of the fuel trim diagnostic Conditions for Setting the DTC D No Tech 2 test is being run D None of the follow...

Страница 1107: ...Symptoms for additional information on diagnosing intermittent problems DTC P0175 Fuel Trim System Rich Bank 2 Step Action Value s Yes No 1 Was the On Board Diagnostic OBD System Check performed Go t...

Страница 1108: ...ire replacement Verify repair Go to Step 12 12 1 Ignition ON engine OFF 2 Monitor the TP Angle display on the Tech 2 while slowly depressing the accelerator pedal Does the TP Angle display increase st...

Страница 1109: ...lates a problem repair as necessary refer to Fuel Metering System Did the Injector Balance Test isolate a problem requiring repair Verify repair Go to Step 20 20 1 Remove and visually physically inspe...

Страница 1110: ...Sets D The PCM will illuminate the malfunction indicator lamp MIL the first time the fault is detected D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in t...

Страница 1111: ...ge to the injector is OK but the driver circuit is grounded at all times This step determines if the circuit is shorted to ground or the PCM is faulty 9 The reading should be about 12 14m 10 Locating...

Страница 1112: ...he injector side of the harness connect an ohmmeter between the positive wire red with blue tracer and the wire for cylinder 1 green with white tracer Does the ohmmeter indicate continuity Go to Step...

Страница 1113: ...Sets D The PCM will illuminate the malfunction indicator lamp MIL the first time the fault is detected D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in t...

Страница 1114: ...ge to the injector is OK but the driver circuit is grounded at all times This step determines if the circuit is shorted to ground or the PCM is faulty 9 The reading should be about 12 14m 10 Locating...

Страница 1115: ...injector side of the harness connect an ohmmeter between the positive wire red with blue tracer and the wire for cylinder 2 green with orange tracer Does the ohmmeter indicate continuity Go to Step 1...

Страница 1116: ...DTC Sets D The PCM will illuminate the malfunction indicator lamp MIL the first time the fault is detected D The PCM will store conditions which were present when the DTC was set as Freeze Frame and i...

Страница 1117: ...ge to the injector is OK but the driver circuit is grounded at all times This step determines if the circuit is shorted to ground or the PCM is faulty 9 The reading should be about 12 14m 10 Locating...

Страница 1118: ...ctor 2 At the injector side of the harness connect an ohmmeter between the positive wire red with blue tracer and the wire for cylinder 3 green Does the ohmmeter indicate continuity Go to Step 11 Go t...

Страница 1119: ...DTC Sets D The PCM will illuminate the malfunction indicator lamp MIL the first time the fault is detected D The PCM will store conditions which were present when the DTC was set as Freeze Frame and i...

Страница 1120: ...ge to the injector is OK but the driver circuit is grounded at all times This step determines if the circuit is shorted to ground or the PCM is faulty 9 The reading should be about 12 14m 10 Locating...

Страница 1121: ...2 At the injector side of the harness connect an ohmmeter between the positive wire red with blue tracer and the wire for cylinder 4 green red Does the ohmmeter indicate continuity Go to Step 11 Go t...

Страница 1122: ...inate the malfunction indicator lamp MIL the first time the fault is detected D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data Co...

Страница 1123: ...ge to the injector is OK but the driver circuit is grounded at all times This step determines if the circuit is shorted to ground or the PCM is faulty 9 The reading should be about 12 14m 10 Locating...

Страница 1124: ...e injector side of the harness connect an ohmmeter between the positive wire red with blue tracer and the wire for cylinder 5 green with black tracer Does the ohmmeter indicate continuity Go to Step 1...

Страница 1125: ...C Sets D The PCM will illuminate the malfunction indicator lamp MIL the first time the fault is detected D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in...

Страница 1126: ...ge to the injector is OK but the driver circuit is grounded at all times This step determines if the circuit is shorted to ground or the PCM is faulty 9 The reading should be about 12 14m 10 Locating...

Страница 1127: ...injector side of the harness connect an ohmmeter between the positive wire red with blue tracer and the wire for cylinder 6 green with yellow tracer Does the ohmmeter indicate continuity Go to Step 1...

Страница 1128: ...Substitute a known good coil Swap the ignition coils and retest If the misfire follows the coil replace the ignition coil If the misfire is random check for the following conditions D System grounds...

Страница 1129: ...e EGR feed pipes D ION Sensing Module 2 If a problem is found repair the vacuum leak as necessary Did your inspection reveal a vacuum leak Verify repair Go to Step 5 5 1 Visually and physically inspec...

Страница 1130: ...k plug s as necessary Did your inspection reveal a problem Verify repair Go to Step 12 12 1 Disconnect the MAF sensor electrical connector 2 Operate the vehicle in closed loop while monitoring the BAN...

Страница 1131: ...ct camshaft D Leaking or sticky valves or rings D Excessive valve deposits D Weak valve springs D Incorrect valve timing D A leaking head gasket D A loose or broken motor mount 2 If a problem is found...

Страница 1132: ...by disconnecting the PCM battery feed Diagnostic Aids Check for the following conditions D System grounds Ensure all connections are clean and properly tightened D Injector Perform the injector coil...

Страница 1133: ...inatio n Diagnosis chart in Engine Mechanical Diagnosis Go to Step 9 9 1 Visually inspect the spark plug insulator for cracks carbon tracking or other damage 2 If the spark plug is damaged replace the...

Страница 1134: ...onnecting the PCM battery feed Diagnostic Aids Check for the following conditions D System grounds Ensure all connections are clean and properly tightened D Injector Perform the injector coil balance...

Страница 1135: ...inatio n Diagnosis chart in Engine Mechanical Diagnosis Go to Step 9 9 1 Visually inspect the spark plug insulator for cracks carbon tracking or other damage 2 If the spark plug is damaged replace the...

Страница 1136: ...onnecting the PCM battery feed Diagnostic Aids Check for the following conditions D System grounds Ensure all connections are clean and properly tightened D Injector Perform the injector coil balance...

Страница 1137: ...inatio n Diagnosis chart in Engine Mechanical Diagnosis Go to Step 9 9 1 Visually inspect the spark plug insulator for cracks carbon tracking or other damage 2 If the spark plug is damaged replace the...

Страница 1138: ...onnecting the PCM battery feed Diagnostic Aids Check for the following conditions D System grounds Ensure all connections are clean and properly tightened D Injector Perform the injector coil balance...

Страница 1139: ...inatio n Diagnosis chart in Engine Mechanical Diagnosis Go to Step 9 9 1 Visually inspect the spark plug insulator for cracks carbon tracking or other damage 2 If the spark plug is damaged replace the...

Страница 1140: ...onnecting the PCM battery feed Diagnostic Aids Check for the following conditions D System grounds Ensure all connections are clean and properly tightened D Injector Perform the injector coil balance...

Страница 1141: ...inatio n Diagnosis chart in Engine Mechanical Diagnosis Go to Step 9 9 1 Visually inspect the spark plug insulator for cracks carbon tracking or other damage 2 If the spark plug is damaged replace the...

Страница 1142: ...disconnecting the PCM battery feed Diagnostic Aids Check for the following conditions D System grounds Ensure all connections are clean and properly tightened D Injector Perform the injector coil bal...

Страница 1143: ...gnosis chart in Engine Mechanical Diagnosis Go to Step 9 9 1 Visually inspect the spark plug insulator for cracks carbon tracking or other damage 2 If the spark plug is damaged replace the spark plug...

Страница 1144: ...e fault is detected D The PCM calculates an air flow value based on idle air control valve position throttle position RPM and barometric pressure D The PCM will store condition which were present when...

Страница 1145: ...r to Diagnostic Aids 3 1 Ignition OFF 2 Disconnect the ION sensing module 3 Disconnect the PCM Is the action complete Go to Step 4 4 Check the ION sensing harness between the PCM F68 and ION sensing m...

Страница 1146: ...tion complete Verify repair Go to Step 10 11 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to ON Vehicle Service in Power Control Module and Sensors for procedures And also re...

Страница 1147: ...et Conditions for Setting the DTC D Engine is running D Extra or missing pulse is detected between consecutive 58X reference pulses D Above condition is detected in 10 of 100 crankshaft rotations Acti...

Страница 1148: ...onnection D Damaged harness Inspect the wiring harness for damage If the harness appears to be OK disconnect the PCM turn the ignition on and observe a voltmeter connected to the 58X reference circuit...

Страница 1149: ...the PCM and CKP sensor 2 Connect a DVM to measure voltage on the 58X reference circuit at the PCM connector 3 Observe the voltage while cranking the engine Is the voltage near the specified value 2 5...

Страница 1150: ...reference circuit DTC P0337 will set Conditions for Setting the DTC D No camshaft position CMP sensor DTCs are set D Engine cranking D Crankshaft position CKP sensor signal is not present between two...

Страница 1151: ...Step 2 Go to OBD System Check 2 Attempt to start the engine Does the engine start Go to Step 3 Go to Chart 3 3 1 Review and record Failure Records information 2 Clear DTC P0337 3 Start the engine and...

Страница 1152: ...drip out Is the action complete Verify repair 11 Check the connections at the PCM and replace the terminals if necessary Did any terminals require replacement Verify repair Go to Step 12 12 Replace t...

Страница 1153: ...iate injector sequence without the CMP signal with a one in six chance that injector sequence is correct The engine will continue to start and run normally although the misfire diagnostic will be affe...

Страница 1154: ...al to wire connection D Damaged harness Inspect the wiring harness for damage If the harness appears to be OK disconnect the PCM turn the ignition on and observe a voltmeter connected to the CMP signa...

Страница 1155: ...4 6 V Go to Step 11 Go to Step 8 5 If the voltage measured in step 3 was less than 4 6 volts proceed directly to step 6 without completing this step If the voltage in step 3 was greater than 4 6 V re...

Страница 1156: ...ve the CMP sensor 2 Place a magnet on the CMP sensor If you use a magnet that is too small to cover the face of the sensor test on every part of the sensor face because only a small area will respond...

Страница 1157: ...the PCM does not receive pulses on the CMP reference circuit DTC P0342 will set and the PCM will initiate injector sequence without the CMP signal with a one in six chance that injector sequence is co...

Страница 1158: ...step number s on the Diagnostic Chart 2 Ensures that the fault is present 14 Determines whether the fault is being caused by a damaged camshaft or a faulty PCM The voltage measured in this step should...

Страница 1159: ...e CMP sensor connector with a test light to ground Does the DVM voltage display switch between 0 and approximately 5 volts when the test light is touched to the CMP sensor signal circuit Go to Step 12...

Страница 1160: ...spond to this test Does the DVM display a voltage near the specified value 0 V Go to Step 14 Go to Step 13 13 Replace the camshaft position sensor Is the action complete Verify repair 14 Replace the P...

Страница 1161: ...The ignition is ON D The engine is turning determined by the 58X crankshaft position input signal D The output voltage is not equal to 5 volts when output is ON D The output voltage is not equal to 0...

Страница 1162: ...5 Note the test result Does the Tech 2 indicate DTC P0351 failed this ignition cycle Go to Step 3 Go to Diagnostic Aids 3 Check for faulty connection at ignition coil Was a problem found Verify repai...

Страница 1163: ...3 12 Repair the open ignition control circuit Is the action complete Verify repair 13 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control...

Страница 1164: ...The ignition is ON D The engine is turning determined by the 58 X crankshaft position input signal D The output voltage is not equal to 5 volts when output is ON D The output voltage is not equal to...

Страница 1165: ...Note the test result Does the Tech 2 indicate DTC P0352 failed this ignition cycle Go to Step 3 Go to Diagnostic Aids 3 Check for faulty connection at ignition coil Was a problem found Verify repair G...

Страница 1166: ...3 12 Repair the open ignition control circuit Is the action complete Verify repair 13 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control...

Страница 1167: ...The ignition is ON D The engine is turning determined by the 58X crankshaft position input signal D The output voltage is not equal to 5 volts when output is ON D The output voltage is not equal to 0...

Страница 1168: ...lt Does the Tech 2 indicate DTC P0353 failed this ignition cycle Go to Step 3 Go to Diagnostic Aids 3 Check for faulty connection at ignition coil Was a problem found Verify repair Go to Step 4 4 Chec...

Страница 1169: ...3 12 Repair the open ignition control circuit Is the action complete Verify repair 13 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control...

Страница 1170: ...The ignition is ON D The engine is turning determined by the 58X crankshaft position input signal D The output voltage is not equal to 5 volts when output is ON D The output voltage is not equal to 0...

Страница 1171: ...lt Does the Tech 2 indicate DTC P0354 failed this ignition cycle Go to Step 3 Go to Diagnostic Aids 3 Check for faulty connection at ignition coil Was a problem found Verify repair Go to Step 4 4 Chec...

Страница 1172: ...12 Repair the open in ignition control circuit Is the action complete Verify repair 13 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Contr...

Страница 1173: ...D The ignition is ON D The engine is turning determined by the 58X crankshaft position input signal D The output voltage is not equal to 5 volts when output is ON D The output voltage is not equal to...

Страница 1174: ...lt Does the Tech 2 indicate DTC P0355 failed this ignition cycle Go to Step 3 Go to Diagnostic Aids 3 Check for faulty connection at ignition coil Was a problem found Verify repair Go to Step 4 4 Chec...

Страница 1175: ...3 12 Repair the open ignition control circuit Is the action complete Verify repair 13 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control...

Страница 1176: ...e ignition is ON D The engine is turning determined by the 58X crankshaft position input signal D The output voltage is not equal to 5 volts when output is ON D The output voltage is not equal to 0 vo...

Страница 1177: ...lt Does the Tech 2 indicate DTC P0356 failed this ignition cycle Go to Step 3 Go to Diagnostic Aids 3 Check for faulty connection at ignition coil Was a problem found Verify repair Go to Step 4 4 Chec...

Страница 1178: ...3 12 Repair the open ignition control circuit Is the action complete Verify repair 13 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control...

Страница 1179: ...or VSS MAP sensor EGR Pintle Position sensor ECT sensor misfire or automatic transmission DTCs set D Engine coolant temperature is greater than 60 C 140 F D Ignition voltage between 11 5 and 16 volts...

Страница 1180: ...of excessive heat check the exhaust system for blockage possibly a plugged catalytic converter using the Restricted Exhaust System Check Test Description Number s below refer to the step number s on t...

Страница 1181: ...6 6 1 Remove the EGR valve 2 Visually and physically inspect the pintle valve passages and the adapter for excessive deposits or any kind of a restriction 3 If a problem is found clean or replace EGR...

Страница 1182: ...cords data Conditions for Clearing the MIL DTC D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present...

Страница 1183: ...terminals Go to Step 4 Go to Step 5 4 Repair the damaged pin or terminal Is the action complete Verify repair 5 1 Remove EGR valve from Engine 2 Inspect EGR valve whether there is any foreign material...

Страница 1184: ...D The PCM will illuminate the malfunction indicator lamp MIL as soon as failure detected after consecutive 2nd trip in which the fault is detected D The PCM will store conditions which were present wh...

Страница 1185: ...pect EGR valve whether there is any excessive carbon deposit on EGR shaft Was excessive carbon deposit on EGR valve shaft Go to Step 6 Go to Step 7 6 1 Clean up EGR valve shaft and inside of EGR valve...

Страница 1186: ...on as failure detected D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in Failure Records data Conditions for Clearing the MIL DTC D The PCM will turn the M...

Страница 1187: ...EL and ground Did the DVM indicate the specified value 4 6 V Go to Step 6 Go to Step 7 6 1 Disconnect the EGR harness connector 2 Measure resistance between terminal 5 Volt reference wire and ground W...

Страница 1188: ...the EGR pintle position circuit and ground Is the measured voltage near the specified value Less than 0 1 V Go to Step 17 Go to Step 16 16 Check for a short circuit between other wires and the pintle...

Страница 1189: ...etected D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in Failure Records data Conditions for Clearing the MIL DTC D The PCM will turn the MIL OFF on the t...

Страница 1190: ...VM to check the voltage at the 5 volt reference wire RED YEL Did the DVM indicate the specified value 4 6 V Go to Step 8 Go to Step 6 6 1 Ignition ON 2 At the PCM connector backprove with a DVM at the...

Страница 1191: ...e short circuit at EGR harness between RED YEL to RED YEL or GRN YEL RED to BLK YEL 2 Replace EGR harness Is the action complete Verify repair 14 Replace EGR harness Is the action complete Verify repa...

Страница 1192: ...catalyst s oxygen storage capacity is below the acceptable threshold D Intake Air temperature is between 10 C 14 F and 70 C 158 F Action Taken When the DTC Sets D The PCM will illuminate the malfunct...

Страница 1193: ...Allow the engine to warm completely D With the vehicle in Park monitor mass air flow on the Tech 2 and hold part throttle to maintain a reading of over 12 g second for at least 2 minutes This will ac...

Страница 1194: ...HO2S 2 2 Ensure that the Bank 1 HO2S 2 is secure and that the pigtail and wiring harness is not contacting the exhaust pipe or is not otherwise damaged 3 If a problem is found repair as necessary Did...

Страница 1195: ...S 2 sensor If the PCM detects a level of Bank 2 HO2S 2 activity that indicates the catalyst is no longer operating efficiently DTC P0430 will be set Conditions for Setting the DTC D No related DTCs D...

Страница 1196: ...y be encountered in areas where test conditions cannot be maintained easily especially in urban areas To minimize the amount of driving required to complete the DTC P0430 Status This Ign test use the...

Страница 1197: ...O2S 2 2 Ensure that the Bank 2 HO2S 2 is secure and that the pigtail and wiring harness is not contacting the exhaust pipe or is not otherwise damaged 3 If a problem is found repair as necessary Did y...

Страница 1198: ...following conditions D Disconnected or faulty fuel tank pressure sensor D Missing or faulty fuel cap D Disconnected damaged pinched or blocked EVAP purge line D Disconnected or damaged EVAP vent hose...

Страница 1199: ...tion that caused the DTC to be set occurs This may assist in diagnosing the condition Test Description Number s below refer to the step number s on the Diagnostic Chart 2 If an EVAP canister vent sole...

Страница 1200: ...r line D Restricted EVAP purge line 2 If a problem is found repair as necessary Was a problem found Verify repair Go to DTC P0452 or DTC P0453 7 1 Visually physically check for the following condition...

Страница 1201: ...vel over a given time period all other variables remaining constant A small leak in the system will cause DTC P0442 to be set Conditions for Setting the DTC D No TP sensor ECT sensor Tank pressure sen...

Страница 1202: ...alue s Yes No 1 Was the On Board Diagnostic OBD System Check performed Go to Step 2 Go to OBD System Check 2 1 Ignition OFF 2 Remove the fuel cap 3 Ignition ON 4 Observe Fuel Tank Pressure on the Tech...

Страница 1203: ...or the following conditions D Missing or faulty fuel cap D Disconnected or leaking fuel tank vapor line D Disconnected or damaged EVAP purge line 2 If a problem is found repair as necessary Was a prob...

Страница 1204: ...nt solenoid stuck closed D Plugged kinked or pinched vent hose D Shorted EVAP canister vent solenoid driver circuit D Plugged evaporative canister If any of these conditions are present DTC P0446 will...

Страница 1205: ...bient pressure 4 Verifies that the fuel tank pressure sensor accurately reacts to EVAP system pressure changes 6 Checks for a blocked EVAP canister DTC P0446 EVAP Canister Vent Blocked Step Action Val...

Страница 1206: ...nister vent solenoid for kinks pinched areas or any other form of blockage 2 If a problem is found repair as necessary Was a problem found Go to Step 9 Go to Step 7 7 Replace the EVAP canister vent so...

Страница 1207: ...ng the MIL DTC D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present D A history DTC P0402 will clea...

Страница 1208: ...to Step 4 Go to Step 10 4 1 Ignition OFF 2 Connect the PCM connector to the PCM 3 Backprobe with a DVM at fuel tank pressure sensor between 5 V reference terminal and sensor ground terminal Was the v...

Страница 1209: ...the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control Module and Sensors for procedures And also refer to latest Service Bulletin Check to see if t...

Страница 1210: ...a Conditions for Clearing the MIL DTC D The PCM will turn the MIL OFF on the third consecutive trip cycle during which the diagnostic has been run and the fault condition is no longer present D A hist...

Страница 1211: ...o Step 4 Go to Step 10 4 1 Ignition OFF 2 Connect the PCM connector to the PCM 3 Disconnect sensor harness at fuel pressure sensor Measure voltage with a DVM at the end of the tank pressure wiring bet...

Страница 1212: ...ce the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control Module and Sensors for procedures And also refer to latest Service Bulletin Check to see i...

Страница 1213: ...e in vacuum level over a given time period all other variables remaining constant A very small leak in the system will cause DTC P0456 to be set Conditions for setting the DTC D No MAP DTC s set D No...

Страница 1214: ...Ignition OFF 2 Remove the fuel cap 3 Ignition ON 4 Observe Fuel Tank Pressure on the Tech 2 Does the Tech 2 indicate Fuel Tank Pressure at the specified value 1 51V Go toStep 3 Go toFuel Tank Pressure...

Страница 1215: ...ery Small Leak Cont d Step No Yes Value s Action 7 1 Visually physically check for the following conditions D Disconnected or leaking fuel tank vapor line D Disconnected or damage EVAP purge line 2 If...

Страница 1216: ...e connection DTC P0462 is set Conditions for Setting the DTC D Fuel tank level slosh test is completed D Fuel tank level main test is completed D Fuel tank level data is valid D Fuel tank level signal...

Страница 1217: ...E 348 TROOPER 6VE1 3 5L ENGINE DRIVEABILITY AND EMISSIONS Test Description Number s below refer to the step number s on the Diagnostic Chart 8 The following chart can be used to check the sending unit...

Страница 1218: ...ly wire at the sensor harness Is the voltage approximately equal to the value measured in Step 4 Go to Step 5 Go to Step 9 5 Check for open or high resistance connection in the ground wire between the...

Страница 1219: ...is shorted to ground DTC P0463 is set Conditions for Setting the DTC D Fuel tank level slosh test is completed D Fuel tank level main test is completed D Fuel tank level data is valid D Fuel tank leve...

Страница 1220: ...to a voltage source Go to Step 4 Go to Step 5 4 Repair short to voltage between the sensor and the PCM Is the repair complete Verify repair 5 With the negative DVM lead connected to ground use the pos...

Страница 1221: ...lfunction indicator lamp MIL the first time the fault is detected D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in the Failure Records data Conditions for...

Страница 1222: ...n ON sensor disconnected 2 Using a DVM measure at the VSS connector between ground and voltage supply Was the measurement near the specified value Battery voltage Go to Step 7 Go to Step 6 6 Repair th...

Страница 1223: ...rner of the blue connector The black red wire is the VSS ground Use a terminal adapter to attach a jumper to ground to the black red VSS ground wire at the transmission side of the blue connector 7 Ra...

Страница 1224: ...Engine coolant temperature ECT is above 50 C D Ignition voltage is between 9 5 volts and 16 7 volts D The throttle is closed D EVAP purge duty cycle more than 10 D All conditions are met for 10 second...

Страница 1225: ...le plate D Throttle body with lever Check for objects send round the throttle spring lever that lever is smooth movement and spring lever has not excessive play Do any of the above require a repair Re...

Страница 1226: ...ND 4 6km SIG DND change resistance Verify repair Go toStep 8 8 Replace the acceleration position sensor Is the action complete Go toStep 9 9 Following below the DTCs stored P1125 P1290 P1295 P1299 Go...

Страница 1227: ...is between 9 5 volts and 16 7 volts D The throttle is closed D EVAP purge duty cycle is more than 10 D All conditions are met for 10 seconds D Engine speed is more than 100 200 RPM higher than desire...

Страница 1228: ...bore and on the throttle plate D Throttle body with lever Check for objects send round the throttle spring lever that lever is smooth movement and spring lever has not excessive play Do any of the abo...

Страница 1229: ...GND 4 6km SIG DND change resistance Verify repair Go to Step 8 8 Replace the acceleration position sensor Is the action complete Go to Step 9 9 Following below the DTCs stored P1125 P1290 P1295 P1299...

Страница 1230: ...5 minutes Action Taken When the DTC Sets D The PCM will not illuminate the malfunction indicator lamp MIL D The PCM will store as Failure Records conditions which were present when the DTC was set Thi...

Страница 1231: ...Go to Starting Char ging 4 1 Ignition OFF 2 Disconnect the PCM connector at the PCM 3 Using a DVM measure the battery voltage at the PCM connector F 20 and F 57 Is it approximately equal to battery v...

Страница 1232: ...inutes Action Taken When the DTC Sets D The PCM will not illuminate the malfunction indicator lamp MIL D The PCM will store as Failure Records only conditions which were present when the DTC was set T...

Страница 1233: ...specified value 11 5 V Replace battery Go to Step 4 4 1 Turn OFF all the accessories 2 Install a Tech 2 3 Select the ignition voltage parameter on the Tech 2 4 Start the engine and raise the engine RP...

Страница 1234: ...PCM detects an internal program fault check sum error Action Taken When the DTC Sets D The PCM will not illuminate the malfunction indicator lamp MIL D The PCM will store conditions which were presen...

Страница 1235: ...to OBD System Check 2 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control Module and Sensors for procedures ANd also refer to latest Ser...

Страница 1236: ...TC Sets D The PCM will not illuminate the malfunction indicator lamp MIL D The PCM will store conditions which were present when the DTC was set in the Failure Records data only Conditions for Clearin...

Страница 1237: ...p 2 Go to OBD System Check 2 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control Module and Sensors for procedures ANd also refer to late...

Страница 1238: ...will not illuminate the malfunction indicator lamp MIL D The PCM will store conditions which were present when the DTC was set in the Failure Records data only Conditions for Clearing the MIL DTC D T...

Страница 1239: ...Go to OBD System Check 2 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control Module and Sensors for procedures ANd also refer to latest S...

Страница 1240: ...ntly control up to 7 outputs Conditions for Setting the DTC D This code detects inconsistencies between Main CPU A D converters and Watchdog CPU A D converters Action Taken When the DTC Sets D The PCM...

Страница 1241: ...ep 2 Go to OBD System Check 2 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control Module and Sensors for procedures ANd also refer to lat...

Страница 1242: ...eed is below 1000 RPM D Throttle angle is below 10 if engine speed is above 1000 RPM D The MAP sensor indicates an intermittent manifold absolute pressure above 80 kPa for a total of approximately 5 s...

Страница 1243: ...o to Step 6 Go to Step 4 4 Check for a poor sensor ground circuit terminal connection at the MAP sensor Was a problem found Go to Step 9 Go to Step 5 5 Check the MAP signal circuit between the MAP sen...

Страница 1244: ...ngle is above 2 if engine speed is above 1000 RPM D The MAP sensor indicates an intermittent manifold absolute pressure below 11 kPa for a total of approximately 5 seconds over a 16 second period of t...

Страница 1245: ...signal circuit between the MAP sensor connector and the PCM for an intermittent open or short to ground Was a problem found Go to Step 9 Go to Step 7 5 Check for an intermittent short to ground on th...

Страница 1246: ...y 2 5 seconds over a 25 second period of time Action Taken When the DTC Sets D The PCM will substitute a default value for intake air temperature D The PCM will store conditions which were present whe...

Страница 1247: ...ILITY AND EMISSIONS Intake Air Temperature Sensor C F OHMS Temperature vs Resistance Values approximate 100 212 177 80 176 332 60 140 667 45 113 1188 35 95 1802 25 77 2796 15 59 4450 5 41 7280 5 23 12...

Страница 1248: ...nd repair as necessary Was a problem found Verify repair Go to Step 6 6 1 Check the IAT signal circuit between the IAT sensor connector and the PCM for an intermittent open 2 If a problem is found rep...

Страница 1249: ...on indicator lamp MIL D The PCM will store conditions which were present when the DTC was set as Failure Records data only This information will not be stored as Freeze Frame data D The PCM will subst...

Страница 1250: ...emperature Sensor C F OHMS Temperature vs Resistance Values approximate 100 212 177 80 176 332 60 140 667 45 113 1188 35 95 1802 25 77 2796 15 59 4450 5 41 7280 5 23 12300 15 5 21450 30 22 52700 40 40...

Страница 1251: ...ut 0 10 volt for a total of 10 seconds over a 100 second period Action Taken When the DTC Sets D The PCM will not illuminate the malfunction indicator lamp MIL D The PCM will store conditions which we...

Страница 1252: ...15 59 4450 5 41 7280 5 23 12300 15 5 21450 30 22 52700 40 40 100700 DTC P1114 ECT Circuit Intermittent Low Voltage Step Action Value s Yes No 1 Was the On Board Diagnostic OBD System Check performed G...

Страница 1253: ...out 5 volts for a total of 10 seconds over a 100 second period Action Taken When the DTC Sets D The PCM will not illuminate the malfunction indicator lamp MIL D The PCM will store conditions which wer...

Страница 1254: ...DTC to be set occurs This may assist in diagnosing the condition Engine Coolant Temperature Sensor C F OHMS Temperature vs Resistance Values approximate 100 212 177 80 176 332 60 140 667 45 113 1188 3...

Страница 1255: ...nd repair as necessary Was a problem found Verify repair Go to Step 6 6 1 Check the ECT signal circuit between the ECT sensor connector and the PCM for an intermittent open 2 If a problem is found rep...

Страница 1256: ...D A histror DTC P1120 will clear after 40 cosecutive trip cycle during which the warm up cycles have occurred without a fault D DTC P1120 can be cleared using the Tech 2 Clear Info function or by disc...

Страница 1257: ...rted Verify repair Go to Step 12 5 Replace the MAP sensor Is the action complete Verify repair 6 Observe the TP angle reading on the Tech 2 while slowly opening the throttle Does the TP angle increase...

Страница 1258: ...he TP sensor 3 If a problem is found repair wiring harness as necessary Was a problem found Verify repair Go to Step 12 11 Replace the TP sensor Is the action complete Verify repair 12 Replace the PCM...

Страница 1259: ...utive trip cycle during which the warm up cycles have occurred without a fault D DTC P1125 can be cleared using the Tech 2 Clear Info function or by disconnecting the PCM battery feed Diagnostic Aids...

Страница 1260: ...Step 5 Go to Step 6 5 1 Connect a test light between the 5 Voltge supply circuit and the AP1 AP2 AND AP3 sensor signal circuit at the AP sensor harness connector 2 Observe the AP sensor reading on th...

Страница 1261: ...plete Verify repair 9 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to ON Vehicle Service in Power Control Module and Sensors for procedures And also refer to latest Service B...

Страница 1262: ...D Engine coolant temperature ECT is above 50 C 122 F for automatic transmission 75 C 167 F for manual transmission D Engine is operating in closed loop D The engine has been running at least one minut...

Страница 1263: ...1 Was the On Board Diagnostic OBD System Check performed Go to Step 2 Go to OBD System Check 2 IMPORTANT If any DTCs are set except P1153 or P1154 refer to those DTCs before proceeding with this diagn...

Страница 1264: ...ween the high signal circuit and ground Also measure between the low signal circuit and ground Are both voltages in the specified range 3 4 mV Go to Step 18 Go to Step 16 16 1 Ignition OFF 2 Check for...

Страница 1265: ...on complete Verify repair 22 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control Module and Sensors for procedures And also refer to late...

Страница 1266: ...engine has been running at least one minute D Canister purge duty cycle is greater than 2 D Engine speed is between 1500 RPM and 3000 RPM D Mass air flow MAF is between 9 g second and 42 g second D A...

Страница 1267: ...NT If any DTCs are set except P1153 and or P1154 refer to those DTCs before proceeding with this diagnostic chart 1 Idle the engine at operating temperature 2 Operate the vehicle within parameters spe...

Страница 1268: ...high signal circuit and ground 4 Also measure the voltage between the low signal circuit and ground Are both voltages in the specified range 3 4V Go to Step 16 Go to Step 19 16 1 With Bank 1 HO2S 1 d...

Страница 1269: ...n complete Verify repair 22 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control Module and Sensors for procedures And also refer to lates...

Страница 1270: ...ngine is operating in closed loop D Engine coolant temperature ECT is above 50 C 122 F for automatic transmission 75 C 167 F for manual transmission D The engine has been running at least one minute D...

Страница 1271: ...o 1 Was the On Board Diagnostic OBD System Check performed Go to Step 2 Go to OBD System Check 2 IMPORTANT If any DTCs are set except P1133 and or P1134 refer to those DTCs before proceeding with this...

Страница 1272: ...oltage between the high signal circuit and ground Also measure between the low signal circuit and ground Are both voltages in the specified range 3 4V Go to Step 18 Go to Step 16 16 1 Ignition ON 2 Ch...

Страница 1273: ...n complete Verify repair 22 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control Module and Sensors for procedures And also refer to lates...

Страница 1274: ...s greater than 2 D Engine speed is between 1500 RPM and 3000 RPM D Mass air flow is between 9 g second and 42 g second D Above conditions are present for a 3 second monitoring period D 90 seconds afte...

Страница 1275: ...before proceeding with this diagnostic chart 1 Idle the engine at operating temperature 2 Operate the vehicle within parameters specified under Conditions for Setting the DTC criteria included in Diag...

Страница 1276: ...n the high signal circuit and ground Also measure the voltage between the low signal circuit and ground Are both voltages in the specified range 3 4 V Go to Step 16 Go to Step 19 16 1 With Bank 2 HO2S...

Страница 1277: ...n complete Verify repair 22 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control Module and Sensors for procedures And also refer to lates...

Страница 1278: ...r fuel control sensors Conditions for setting the DTC D No related DTCs D The engine coolant temperature is more than 60 C 140 F D Engine is operating in closed loop power enrichment mode for 3 second...

Страница 1279: ...the fuel pressure gauge 3 Start the engine and idle at normal operating temperatur 4 Disconnect the vacuum line going to the fuel pressure regurlator With the engine running is the fuel pressure with...

Страница 1280: ...fuel control sensors Conditions for setting the DTC D No related DTCs D The engine coolant temperature is more than 60 C 140 F D Engine is operating in closed loop power enrichment mode for 3 seconde...

Страница 1281: ...the fuel pressure gauge 3 Start the engine and idle at normal operating temperatur 4 Disconnect the vacuum line going to the fuel pressure regurlator With the engine running is the fuel pressure with...

Страница 1282: ...loop power enrichment mode for 3 seconds D Engine coolant temperature is above 60 C 140 F D While in power enrichment mode the oxygen sensor voltage remains below 400 mV for 3 seconds Action Taken Wh...

Страница 1283: ...to 900 mV It is possible to measure a satisfactory fuel pressure at idle even though the pressure may drop at high flow requirements It may be necessary to watch fuel pressure at high engine load 5 W...

Страница 1284: ...ump relay and crank the engine to relieve the fuel pressure 2 Install the fuel pressure gauge 3 Start the engine and idle at normal operating temperature 4 Disconnect the vacuum line going to the fuel...

Страница 1285: ...which the warm up cycles have occurred without a fault D DTC P1120 can be cleared using the Tech2 Clear Info function or by disconnecting the PCM battery feed Diagnostic Aids An intermittent may be c...

Страница 1286: ...the circuit and see if 5V returns Go to Step 6 Go to Step 5 5 1 Check the MAP signal circuit between the PCM and MAP ground circuit 2 If the MAP signal circuit is open or shorted repair as necessary W...

Страница 1287: ...cuit or 5 volt reference circuit for a poor connection 2 TP2 signal circuit or 5 volt reference circuit for high resistance between the PCM and the TP sensor 3 If a problem is found repair wiring harn...

Страница 1288: ...or pedal arm with spring and excessive deposits in the acceleration pedal arm and on the acceleration pedal Test Description Number s below refer to the step number s on the Diagnostic Chart 2 Visual...

Страница 1289: ...e above require a repair Refer to appropriate section for on vehicle service Go to Step 5 4 Visually physically inspect for the following conditions D Acceleration pedal tampering D Acceleration pedal...

Страница 1290: ...as necessary Was a problem found Verify repair Go to Step 9 9 Replace the acceleration position sensor Is the action complete Go to Step 10 10 Following below the DTCs stored P1125 P1290 P1295 P1299...

Страница 1291: ...will clear after 40 consecutive trip cycle during which the warm up cycles have occurred without a fault D DTC P1271 can be cleared using the Tech 2 Clear Info function or by disconnecting the PCM ba...

Страница 1292: ...tep 6 5 1 Connect a test light between the 5 Voltge supply circuit and the AP sensor signal circuit at the AP1 AP2 sensor harness connector 2 Observe the AP sensor reading on the Tech 2 Is the AP sens...

Страница 1293: ...he PCM IMPORTANT The replacement PCM must be programmed Refer to ON Vehicle Service in Power Control Module and Sensors for procedures And also refer to latest Service Bulletin Check to see if the lat...

Страница 1294: ...will clear after 40 consecutive trip cycle during which the warm up cycles have occurred without a fault D DTC P1272 can be cleared using the Tech 2 Clear Info function or by disconnecting the PCM ba...

Страница 1295: ...6 5 1 Connect a test light between the 5 Voltge supply circuit and the AP sensor signal circuit at the AP2 and AP3 sensor harness connector 2 Observe the AP sensor reading on the Tech 2 Is the AP sen...

Страница 1296: ...e PCM IMPORTANT The replacement PCM must be programmed Refer to ON Vehicle Service in Power Control Module and Sensors for procedures And also refer to latest Service Bulletin Check to see if the late...

Страница 1297: ...will clear after 40 consecutive trip cycle during which the warm up cycles have occurred without a fault D DTC P1273 can be cleared using the Tech 2 Clear Info function or by disconnecting the PCM ba...

Страница 1298: ...5 1 Connect a test light between the 5 Voltge supply circuit and the AP sensor signal circuit at the AP1 and AP3 sensor harness connector 2 Observe the AP sensor reading on the Tech 2 Is the AP senso...

Страница 1299: ...he PCM IMPORTANT The replacement PCM must be programmed Refer to ON Vehicle Service in Power Control Module and Sensors for procedures And also refer to latest Service Bulletin Check to see if the lat...

Страница 1300: ...DTC P1275 will clear after 40 consecutive trip cycle during which the warm up cycles have occurred without a fault D DTC P1275 can be cleared using the Tech 2 Clear Info function or by disconnecting...

Страница 1301: ...he AP sensor reading near the specified value 5V Go to Step 7 Go to Step 8 6 Check the following items 1 AP1 signal circuit for a short to voltage 2 AP1 sensor ground circuit for high resistance betwe...

Страница 1302: ...DTC P1280 will clear after 40 consecutive trip cycle during which the warm up cycles have occurred without a fault D DTC P1280 can be cleared using the Tech 2 Clear Info function or by disconnecting...

Страница 1303: ...he AP sensor reading near the specified value 5V Go to Step 7 Go to Step 8 6 Check the following items 1 AP2 signal circuit for a short to voltage 2 AP2 sensor ground circuit for high resistance betwe...

Страница 1304: ...y DTC P1285 will clear after 40 consecutive trip cycle during which the warm up cycles have occurred without a fault D DTC P1285 can be cleared using the Tech 2 Clear Info function or by disconnecting...

Страница 1305: ...he AP sensor reading near the specified value 5V Go to Step 7 Go to Step 8 6 Check the following items 1 AP3 signal circuit for a short to voltage 2 AP3 sensor ground circuit for high resistance betwe...

Страница 1306: ...ring which the warm up cycles have occurred without a fault D DTC P1290 can be cleared using the Tech 2 Clear Info function or by disconnecting the PCM battery feed Diagnostic Aids An intermittent may...

Страница 1307: ...V Go to Step 5 Go to Step 6 5 1 Connect a test light between the 5 Voltge supply circuit and the AP1 AP2 and AP3 sensor signal circuit at the AP sensor harness connector 2 Observe the AP sensor readin...

Страница 1308: ...e Verify repair 9 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to ON Vehicle Service in Power Control Module and Sensors for procedures And also refer to latest Service Bulle...

Страница 1309: ...ditects that if the systm is in PowerManagement Mode Fail safe Mode Conditions for setting the DTC D The ignition is ON D Power Management Mode is active Fail safe Mode Action Taken When the DTC Sets...

Страница 1310: ...d record Tech 2 Failure Records data 3 Operate the vehicle within Failure Records conditions as noted 4 Using a Tech 2 monitor DTC info for DTC P1295 Does the Tech 2 indicate DTC P1295 failed this ign...

Страница 1311: ...e TP1and TP2 sensor 3 If a problem is found repair wiring harness as necessary Was a problem found Verify repair Go to Step 14 13 Replace the TP sensor Is the action complete Verify repair 14 1 Start...

Страница 1312: ...nosis chart forother sensors in the circuit and see if 5V returns Go to Step 22 Go to Step 21 21 1 Check the MAP signal circuit between the PCM and MAP grund circuit 2 If the MAP signal circuit is ope...

Страница 1313: ...if the system is in ECT Forced Engine Shutdown Mode Fail safe Mode Conditions for setting the DTC D The ignition is ON D ECT Forced Engine Shutdown Mode is active Fail safe Mode Action Taken When the...

Страница 1314: ...d throttle value to the wide open throttle value Closed throttle TP sensor 1 8 10 TP sensor 2 90 92 Wide open throttle TP sensor 1 90 92 TP sensor 2 8 10 Go to Step 8 Go to Step 4 4 1 Ignition OFF 2 D...

Страница 1315: ...e 2 With the engine idling monitor MAF Frequency display on the Tech 2 Is the MAF Frequency below the specified value 6 10 g s Go to Step 16 Go to Step 17 14 1 Ignition OFF 2 Disconnect the MAF sensor...

Страница 1316: ...p 21 Go to Step 20 20 1 Check the MAP signal circuit between the PCM and MAP ground circuit 2 If the MAP signal circuit is open or shorted repair it as necessary Was the MAP signal circuit open or sho...

Страница 1317: ...tatus were detected If missing CQ pulses or multiple CQ pulses or CQ pulse width calculation errors were detected the fail counter will be incremented If the failure counter exceeds the calibration th...

Страница 1318: ...rminal to wire connection D Damaged harness Inspect the wiring harness for damage If the harness appears to be OK observe the moving connectors and wiring harnesses related to the sensor A change in t...

Страница 1319: ...nnector Was a problem found Verify repair Go to Step 6 5 1 Disconnect the ignition coil Is the action complete Go to Step 6 Go to Step 5 6 Check the ION Sensing harness between the ignition coil and I...

Страница 1320: ...the PCM IMPORTANT The replacement PCM must be programmed Refer to ON Vehicle Service in Power Control Module and Sensors for procedures And also refer to latest Service Bulletin Check to see if the l...

Страница 1321: ...between 26kPa and 100 kPa D Fuel level is more than 10 D Engine speed is between 650rpm and 6500rpm D ION Sensing Module circuit is open or shorted signals on the SEC 1 line Action Taken When the DTC...

Страница 1322: ...e Records conditions as noted 4 Using a Tech 2 monitor DTC info for DTC P1311 Does the Tech 2 indicate DTC P1311 failed this ignition Go to Step 3 Refer to Diagnostic Aids 3 1 Ignition OFF 2 Disconnec...

Страница 1323: ...n complete Verify repair Go to Step 10 11 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to ON Vehicle Service in Power Control Module and Sensors for procedures And also refer...

Страница 1324: ...between 26kPa and 100 kPa D Fuel level is more than 10 D Engine speed is between 650rpm and 6500rpm D ION Sensing Module circuit is open or shorted signals on the SEC 2 line Action Taken When the DTC...

Страница 1325: ...ure Records conditions as noted 4 Using a Tech 2 monitor DTC info for DTC P1312 Does the Tech 2 indicate DTC P1312 failed this ignition Go to Step 3 Refer to Diagnostic Aids 3 1 Ignition OFF 2 Disconn...

Страница 1326: ...n complete Verify repair Go to Step 10 11 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to ON Vehicle Service in Power Control Module and Sensors for procedures And also refer...

Страница 1327: ...culates an air flow value based on idle air control valve position throttle position RPM and barometric pressure D The PCM will store condition which were present when the DTC was set as Freeze Frame...

Страница 1328: ...e action complete Go to Step 4 Go to Step 3 4 Check the ION Sensing module harness between the PCM and ION Sensing module circuit at the QC line harness connector Was a problem found Verify repair Go...

Страница 1329: ...lete Verify repair Go to Step 10 11 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to ON Vehicle Service in Power Control Module and Sensors for procedures And also refer to la...

Страница 1330: ...the fault is detected D The PCM calculates an air flow value based on idle air control valve position throttle position RPM and barometric pressure D The PCM will store condition which were present w...

Страница 1331: ...iagnosticAid s 3 1 Ignition OFF 2 Disconnect the ION Sensing module 3 Disconnect the PCM Is the action complete Go to Step 4 Go to Step 3 4 Check the ION Sensing module harness between the PCM and ICS...

Страница 1332: ...e action complete Verify repair Go to Step 10 11 Replace the PCM IMPORTANT IMPORTANT The replacement PCM must be programmed Refer to ON Vehicle Service in Power Control Module and Sensors for procedur...

Страница 1333: ...illuminate the malfunction indicator lamp MIL after consecutive 2nd trip in which the fault is detected D The PCM will store conditions which were present when the DTC was set as Freeze Frame and in...

Страница 1334: ...maged pin or terminal Is the action complete Verify repair 5 1 Remove EGR valve from Engine 2 Inspect EGR valve for any excessive carbon deposit on EGR shaft 3 Inspect for any foreign material inside...

Страница 1335: ...2 Go to Step 10 Verify repair 10 Replace the PCM IMPORTANT The replacement PCM must be programmed Refer to On Vehicle Service in Powertrain Control Module and Sensors for procedures And also refer to...

Страница 1336: ...the EVAP purge solenoid ON DTC P1441 will be set Conditions for Setting the DTC D No active ECT sensor IAT sensor MAP sensor vacuum switch or TP sensor DTCs set D BARO reading is above 85 kPa D Engine...

Страница 1337: ...was originally stored If not the fault is intermittent 5 Checks for a grounded EVAP purge solenoid driver circuit a faulty EVAP vacuum switch or a leaking EVAP purge solenoid valve DTC P1441 EVAP Sys...

Страница 1338: ...er of air separator which is located near the vent solenoid valve Was a problem found Using the Vacuum Hose Routing Diagram repair or re connect the rubber hoses correctly Verify Repair Go to Step 7 7...

Страница 1339: ...ottle actuation mode is not off D MAF reading ETC estimated air flow is less than 40g s for 250 failres within test 1000 test samples 15 6 m sec Action Taken When the DTC Sets D The PCM will illuminat...

Страница 1340: ...tem Check 2 Was the Electric Throttle Control ETC System Check performed Go to Step 3 Go to ETC System Check 3 1 Ignition ON engine OFF 2 Review and record Tech 2 Failure Records data 3 Operate the ve...

Страница 1341: ...r 13 Observe the TP angle reading on the Tech 2 while slowly opening the throttle Does the TP angle increase steadily and evenly from the closed throttle value to the wide open throttle value Closed t...

Страница 1342: ...1and TP2 sensor 3 If a problem is found repair wiring harness as necessary Was a problem found Verify repair Go to Step 18 18 Replace the TP sensor Is the action complete Verify repair 19 Replace the...

Страница 1343: ...test samples 15 6 m sec Action Taken When the DTC Sets D The PCM will illuminate the malfunction indicator lamp MIL the first time the fault is detected D The PCM calculates an air flow value based on...

Страница 1344: ...sing a Tech 2 monitor DTC info for DTC P1515 Does the Tech 2 indicate DTC P1515 failed thisignition Go to Step 4 Refer to Diagnostic Aids 4 Observe the TP angle reading on the Tech 2 while slowly open...

Страница 1345: ...TP2 signal circuit or 5 volt reference circuit for a poor connection 2 TP1 and TP2 signal circuit or 5 volt reference circuit for high resistance between the PCM and the TP1and TP2 sensor 3 If a prob...

Страница 1346: ...ontrol valve position throttle position RPM and barometric pressure D The PCM will store condition which were present when the DTC was set as Freeze Frame and in the Failure Records data Conditions fo...

Страница 1347: ...Step 4 Refer to Diagnostic Aids 4 Observe the TP angle reading on the Tech 2 while slowly opening the throttle Does the TP angle increase steadily and evenly from the closed throttle value to the wide...

Страница 1348: ...TP2 signal circuit or 5 volt reference circuit for a poor connection 2 TP1 and TP2 signal circuit or 5 volt reference circuit for high resistance between the PCM and the TP1 and TP2 sensor 3 If a pro...

Страница 1349: ...longer present D A history DTC P1523 will clear after 40 cosecutive trip cycle during which the warm up cycles have occurred without a fault D DTC P1523 can be cleared using the Tech 2 Clear Info func...

Страница 1350: ...k the DC motor harness between the PCM and DC Motor circuit at the DC motor harness connector Was a problem found Verify repair Go to Step 7 6 Replace the DC motor Is the action complete Verify repair...

Страница 1351: ...he TP1and TP2 sensor 3 If a problem is found repair wiring harness as necessary Was a problem found Verify repair Go to Step 12 11 Replace the TP sensor Is the action complete Verify repair 12 Replace...

Страница 1352: ...fault D DTC P1625 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed Diagnostic Aids Check for the following conditions D P1625 alone stored does not need...

Страница 1353: ...Action Taken When the DTC Sets D The PCM will not illuminate the malfunction indicator lamp MIL D The PCM will store condition which were present when the DTC was set as Freeze Frame and in the Failur...

Страница 1354: ...HT pin Is the voltage in specified range 11 6 12 7V Go to Step 4 Go to Step 5 4 1 Ignition ON engine not running 2 Using a DVM at the PCM side of the connector check the votage at terminal F57 WHT pin...

Страница 1355: ...ction Taken When the DTC Sets D The PCM will not illuminate the malfunction indicator lamp MIL D The PCM will store condition which were present when the DTC was set as Freeze Frame and in the Failure...

Страница 1356: ...pin Is the voltage in specified range 11 6 12 7V Go to Step 4 Go to Step 5 4 1 Ignition ON engine not running 2 Using a DVM at the PCM side of the connector check the votage at terminal F57 WHT pin I...

Страница 1357: ...will clear after 40 consecutive warm up cycles occur without a fault D DTC P1640 can be cleared by using the Tech 2 Clear Info function or by disconnecting the PCM battery feed Diagnostic Aids Check f...

Страница 1358: ...p 7 Go to Step 13 7 1 Leave the PCM connector for the lamp driver circuit disconnected 2 Ignition ON 3 Using a DVM check the voltage at the PCM connector for the affected lamp driver circuit Was the v...

Страница 1359: ...4 14 1 Run the engine at idle 2 Check for battery voltage at the fuse for the affected circuit Was battery voltage available at the fuse Go to Step 10 Go to Step 9 15 Replace the PCM IMPORTANT The rep...

Страница 1360: ...Inspect harness connectors for backed out terminals improper mating broken locks improperly formed or damaged terminals and poor terminal to wire connection D Damaged harness Inspect the wiring harnes...

Страница 1361: ...7 Go to Step 13 7 1 Leave the PCM connector for the lamp driver circuit disconnected 2 Ignition ON 3 Using a DVM check the voltage at the PCM connector for the affected lamp driver circuit Was the vol...

Страница 1362: ...4 1 Run the engine at idle 2 Check for battery voltage at the fuse for the affected circuit Was battery voltage available at the fuse Go to Step 10 Go to Step 9 15 Replace the PCM IMPORTANT The replac...

Страница 1363: ...00 Digital Multimeter connected to a suspected circuit An abnormal voltage when the malfunction occurs is a good indication that there is a fault in the circuit being monitored Use a Tech 2 to help de...

Страница 1364: ...air temperature Are ECT and IAT within the specified value of each other 5 C 9 F Go to Step 10 Go to Step 6 6 1 Using a Tech 2 display the engine coolant temperature and note the value 2 Check the re...

Страница 1365: ...pair as necessary Was a problem found Verify repair Go to Step 15 15 1 Remove the ignition coils and check the ignition coils for cracks or carbon tracking 2 If a problem is found replace affected coi...

Страница 1366: ...em OK Go to Step 6 6 1 Check the the fuel control heated oxygen sensors HO2S B1S1 and B2S1 The fuel control heated oxygen sensors HO2S should respond quickly to different throttle positions If they do...

Страница 1367: ...lectrodes or heavy deposits Refer to Electronic Ignition System NOTE If spark plugs are gas or oil fouled the cause of the fouling must be determined before replacing the spark plugs 2 If a problem is...

Страница 1368: ...exhaust system back pressure Refer to Restricted Exhaust System Check 2 If a problem is found repair as necessary Was a problem found Verify repair Go to Step 20 20 1 Review all diagnostic procedures...

Страница 1369: ...strictions Refer to Air Intake System in ON Vehicle Service 2 Replace the air filter element if necessary Was a repair required Verify repair Go to Step 6 6 1 Check for low fuel pressure Refer to Fuel...

Страница 1370: ...apsed pipes D Inspect the muffler for heat distress or possible internal failure D Check for a possible plugged three way catalytic converter by checking the exhaust system back pressure Refer to Rest...

Страница 1371: ...ch circuit Use a Tech 2 and be sure the Tech 2 indicates that the vehicle is in drive with the gear selector in drive or overdrive 2 If a problem is found diagnose and repair the transmission range sw...

Страница 1372: ...rness as necessary Was a problem found Go to Step 10 Go to Step 16 15 Replace the ION sensing module Is the action complete Verify repair Go to Step 16 16 1 Check fuel pressure Refer to Chart Fuel Sys...

Страница 1373: ...y Was a problem found Verify repair Go to Step 21 21 1 Review all diagnostic procedures within this table 2 If all procedures have been completed and no malfunctions have been found review inspect the...

Страница 1374: ...PCM wiring diagrams in Electrical Diagnosis 2 If a problem is found repair as necessary Was a problem found Verify repair Go to Step 6 6 Observe the long term fuel trim on the Tech 2 Is the long term...

Страница 1375: ...to Step 14 14 1 Check for fuel in the pressure regulator vacuum hose 2 If fuel is present replace the fuel pressure regulator assembly Refer to Fuel Metering System 3 If a problem is found repair as...

Страница 1376: ...iagnosis Was a problem found Verify repair Go to Step 22 22 1 Check for the following engine mechanical items Refer to Engine Mechanical for diagnosis procedures D Low compression D Sticking or leakin...

Страница 1377: ...ively heavy loads being carried D Is acceleration too much too often Was a problem found Go to Step 5 Go to Step 6 5 Review the items in Step 4 with the customer and advise as necessary Is the action...

Страница 1378: ...found repair as necessary Was a problem found Verify repair Go to Step 14 14 Check for proper calibration of the speedometer Does the speed indicated on the speedometer closely match the vehicle spee...

Страница 1379: ...ssary Was the fuel cap installed properly Go to Step 6 Go to Step 13 6 1 Check the fuel pressure Perform the procedure in Fuel System Pressure Test 2 If a problem is found repair as necessary Was a pr...

Страница 1380: ...st System OK Go to Step 17 16 1 Check items that can cause the engine to run lean Refer to Diagnostic Aids in DTC P0171 Diagnostic Support Make any necessary repairs 2 Perform the exhaust emission tes...

Страница 1381: ...ses the symptom Verify repair Go to Step 3 3 Was a visual physical check performed Go to Step 4 Go to Visual Physic al Check 4 1 Check for a short between B and any of the ignition feed circuits 2 If...

Страница 1382: ...ugs and check for wet plugs cracks wear improper gap burned electrodes or heavy deposits Refer to Electronic Ignition System NOTE If spark plugs are gas or oil fouled the cause of the fouling must be...

Страница 1383: ...repair Go to Step 10 10 1 Check the intake and exhaust manifold s for casting flash Refer to Engine Mechanical 2 If a problem is found repair as necessary Was a problem found Verify repair Go to Step...

Страница 1384: ...2 If a problem is found repair as necessary Was a problem found Verify repair Go to Step 6 6 Observe the long term fuel trim on the Tech 2 Is the long term fuel trim significantly in the negative ran...

Страница 1385: ...ssure regulator assembly Refer to Fuel Metering System 3 If a problem is found repair as necessary Was a problem found Verify repair Go to Step 15 15 1 Check for proper ignition voltage output with sp...

Страница 1386: ...Mechanical for diagnosis procedures D Low compression D Sticking or leaking valves D Worn camshaft lobe s D Camshaft drive belt slipped or stripped D Incorrect valve timing D Worn rocker arms D Broke...

Страница 1387: ...don t check them for silicon or other contaminants from fuel or use of improper RTV sealant The sensors may have a white powdery coating Silicon contamination causes a high but false HO2S signal volt...

Страница 1388: ...k the ignition coils for cracks or carbon tracking 2 If a problem is found repair as necessary Was a problem found Verify repair Go to Step 14 14 1 Remove spark plugs and check for wet plugs cracks we...

Страница 1389: ...found repair as necessary Was a problem found Verify repair Go to Step 18 18 1 Review all diagnostic procedures within this table 2 If all procedures have been completed and no malfunctions have been...

Страница 1390: ...verter Possible faults include D Collapsed pipe D Heat distress D Internal muffler failure Is the action complete Verify repair 4 1 Install the Bank 1 HO2S 2 2 Install the Exhaust Backpressure Tester...

Страница 1391: ...erter Possible faults include D Collapsed pipe D Heat distress D Internal muffler failure Is the action complete Verify repair 4 1 Install the Bank 2 HO2S 2 2 Install the Exhaust Back pressure Tester...

Страница 1392: ...codes set Customer complains of harsh or soft shift poor performance delayed or no engagement into drive or reverse transmission fluid leak transmission noise or vibration or improper TCC operation Au...

Страница 1393: ...TC system check 3 Fuel injector and fuel injector balance test 4 EVAP emission canister purge valve check 5 Ignition system 6 EGR operation MAP Output Check Throttle Linkage EGR System Check A C Clutc...

Страница 1394: ...stem diagnosis 4 Fuel injector and fuel injector balance test 5 EGR operation EGR system check Exhaust System Diagnosis Intake Casting Flash Ignition System Check Misfire 1 OBD system check 2 Ignition...

Страница 1395: ...emove the CMP sensor from the cylinder head Inspection Procedure 1 Inspect the sensor O ring for cracks or leaks 2 Replace the O ring if it is worn or damaged 3 Lubricate the new O ring with engine oi...

Страница 1396: ...h engine oil 4 Install the lubricated O ring Installation Procedure 1 Install the CKP sensor in the engine block 2 Install the CKP sensor mounting bolt Tighten D Tighten the mounting bolt to 9 N m 78...

Страница 1397: ...the ECT sensor in the coolant crossover Tighten D Tighten the ECT sensor to 30 N m 22 lb ft 014RY00002 3 Connect the electrical connector 014RY00003 4 Fill the radiator with coolant Refer to Draining...

Страница 1398: ...ahead of the right hand catalytic converter TS22912 D Bank 1 sensor 2 is mounted behind the right hand catalytic converter TS22913 D Bank 2 sensor 1 is mounted on the exhaust pipe ahead of the left ha...

Страница 1399: ...l connector for grease dirt corrosion and bare wires or worn insulation 2 Inspect the louvered end of the sensor for grease dirt or other contaminations 060RY00017 Installation Procedure IMPORTANT D A...

Страница 1400: ...m the intake air duct by using a rocking motion while pulling the sensor Installation Procedure 1 Install the IAT sensor into the grommet in the intake air duct 2 Correct the IAT electrical connector...

Страница 1401: ...ct the electrical connector from the MAF sensor TS23740 3 Loosen the clamps which secure the intake air duct and the air cleaner to the MAF sensor 4 Remove the intake air duct from the MAF sensor 5 Re...

Страница 1402: ...Remove the bolt securing the MAP sensor to the mounting bracket on the common chamber 4 Remove the MAP sensor from the mounting bracket 055RW002 Installation Procedure 1 Install the MAP sensor in the...

Страница 1403: ...leaving the person highly charged with the opposite polarity Static charges can cause damage therefore it is important to use care when handling and testing electronic components NOTE To prevent poss...

Страница 1404: ...ntains program and calibration information that the PCM needs to control powertrain operation EEPROM Programming 1 Set up Ensure that the following conditions have been met D The battery is fully char...

Страница 1405: ...closed throttle D The voltage should be under 0 85 volt D If the reading is greater than 0 85 volt check the throttle shaft to see if it is binding Installation Procedure 1 Install the TP sensor on th...

Страница 1406: ...or warping Replace the VSS if the electrical connector is corroded or warped 2 Inspect the VSS driven gear for chips breaks or worn condition Replace the VSS if the driven gear is chipped broken or w...

Страница 1407: ...02 Legend 1 Air Cleaner Housing 2 Air Filter Element 3 Air Cleaner Lid Installation Procedure 1 Install the air cleaner housing in the vehicle with the retaining bolts 2 Install the air filter element...

Страница 1408: ...ve the two screws from the accelerator pedal assembly 101RY00007 4 Remove the accelerator pedal assembly from the bulkhead Installation Procedure 1 Install the accelerator pedal assembly on the bulkhe...

Страница 1409: ...n Procedure NOTE Replace the fuel filler cap with the same type of filler cap that was originally installed on the vehicle D Check the seal ring in the filler cap for any abnormality and for seal cond...

Страница 1410: ...r body D The fuel filter body is damaged D The fuel filter is clogged with dirt or sediment Installation Procedure 1 Install the fuel filter in the correct direction 2 Install the bolt on the fuel fil...

Страница 1411: ...ten D Tighten the drain plug to 20 N m 14 lb ft TS22907 4 Disconnect the wiring connector from the fuel gauge unit TS23771 5 Remove the fuel gauge unit retaining screws 6 Remove the fuel gauge unit D...

Страница 1412: ...lectrical connector pins or the fuel injector nozzles The fuel injector is an electrical component and should not be immersed in any type of cleaner as this may damage the fuel injector IMPORTANT Fuel...

Страница 1413: ...Relief Procedure CAUTION To reduce the risk of fire and personal injury there are necessary to relieve the fuel system pressure filler and gauge unit before servicing the fuel system components CAUTI...

Страница 1414: ...ce the fuel pump gasket 2 Inspect the in tank fuel filter for tears or evidence of dirt debris or water in the fuel If any of these conditions are found replace the in tank fuel filter Installation Pr...

Страница 1415: ...y tips D Fittings should be capped and holes plugged during servicing to prevent dirt and other contaminants from entering open lines and passages IMPORTANT An eight digit identification number is sta...

Страница 1416: ...re Regulator section 3 Install the common chamber Refer to common chamber in engine Mechanical section 014RW164 4 Connect the vacuum hose on Canister VSV and positive crankcase ventilation hose 5 Conn...

Страница 1417: ...s to prevent dust from entering the hoses TS23769 15 Remove the fuel tank retaining bolts on both sides 16 Remove the fuel tank TS23770 Installation Procedure 1 Install the fuel tank D Place the flang...

Страница 1418: ...he tank 12 Connect the air breather hose at the tank TS23796 13 Fill the fuel tank with fuel 14 Tighten the fuel filler cap 15 Connect the negative battery cable Throttle Body TB Removal Procedure 1 D...

Страница 1419: ...the manifold D Do not leave any scratches in the aluminum casting Installation Procedure 1 Install the TP sensor Refer to Throttle Position TP Sensor section 2 Install the gasket on the common chambe...

Страница 1420: ...Cross threading or failure to fully seat the spark plug can cause plug overheating exhaust blow by gases or thread damage Do not overtighten the spark plugs Over tightening can cause aluminum threads...

Страница 1421: ...slot on the forward side of the fuel pump relay D The screwdriver blade will release the catch inside D08RW131 4 Pull the relay straight up and out of the fuse and relay box TS23986 Installation Proc...

Страница 1422: ...apor connector and the purge hose from the EVAP canister vent solenoid 014RW147 4 Remove the retaining two bolts on the mounting bracket and slide the canister out of mounting bracket 014RW146 Inspect...

Страница 1423: ...nect the negative battery cable 2 Slide out the EVAP canister vent solenoid from mounting bracket 014RW149 3 Disconnect the connector and hose 014RW148 Inspection Procedure 1 Check for cracks or leaks...

Страница 1424: ...of rot Installation Procedure 1 Install the rubber grommet on the fuel pump assembly 2 Install the fuel tank vapor pressure sensor on the fuel pump assembly D Insert the sensor nipple firmly into the...

Страница 1425: ...ge solenoid 014RW137 4 Connect the electrical connector to the EVAP canister purge solenoid 014RW138 Fuel Tank Vent Valve Removal and Installation Procedure Refer to Fuel Pump section Linear Exhaust G...

Страница 1426: ...ack to release the hose 2 Pull the PCV valve from the rubber grommet in the right valve cover 014RW097 Inspection Procedure Before inspecting the PCV valve make sure that the hoses are connected prope...

Страница 1427: ...ack seals Use an appropriate connector test adapter kit which contains an assortment of flexible connectors used to probe terminals during diagnosis Use an appropriate fuse remover and test tool for r...

Страница 1428: ...Procedure 1 Splice the wires using splice clips and rosin core solder 2 Wrap each splice to insulate 3 Wrap the splice with mylar and with the drain uninsulated wire 049 4 Tape over the whole bundle...

Страница 1429: ...Use splice clips and rosin core solder in order to splice the two wires together 052 2 Cover the splice with tape in order to insulate it from the other wires 053 3 Twist the wires as they were before...

Страница 1430: ...minal may be bent or deformed Unlike standard blade terminals these terminals cannot be straightened after they have been improperly bent 071 3 Cut the wire immediately behind the cable seal 072 Insta...

Страница 1431: ...35689 Terminal Remover Removal Procedure Some connectors use terminals called Metri Pack Series 150 These may be used at the engine coolant temperature ECT sensor 1 Slide the seal 1 back on the wire...

Страница 1432: ...ate true sequential fuel injection SFI mode of operation If the PCM detects an incorrect CMP signal while the engine is running DTC P0341 will set If the CMP signal is lost while the engine is running...

Страница 1433: ...to set The PCM can also detect HO2S response problems If the response time of an HO2S is determined to be too slow the PCM will store a DTC that indicates degraded HO2S performance 060RY00030 Catalys...

Страница 1434: ...close to each other A fault in the IAT sensor circuit will set DTC P0112 or DTC P0113 Linear Exhaust Gas Recirculation EGR Control The PCM monitors the exhaust gas recirculation EGR actual position a...

Страница 1435: ...through resistances in the PCM which are so high in value that a test light will not light when connected to the circuit In some cases even an ordinary shop voltmeter will not give an accurate readin...

Страница 1436: ...o the latest Techline information on reprogramming or flashing procedures Throttle Position TP Sensor The throttle position TP sensor is a potentiometer connected to the throttle shaft on the throttle...

Страница 1437: ...ll exists it may be diagnosed in the normal manner Electrostatic Discharge Damage Electronic components used in the PCM are often designed to carry very low voltage Electronic components are susceptib...

Страница 1438: ...the fuel injectors de energized as long as the throttle remains above 80 and the engine speed is below 800 RPM If the throttle position becomes less than 80 the PCM again begins to pulse the injectors...

Страница 1439: ...s in order to determine the fuel needs of the engine Fuel is delivered under one of several conditions called modes All modes are controlled by the PCM Fuel Pressure Regulator The fuel pressure regula...

Страница 1440: ...temperature ECT sensor and the throttle position TP sensor to determine the proper air fuel ratio for starting The PCM controls the amount of fuel delivered in the starting mode by adjusting how long...

Страница 1441: ...d at each spark plug The coil at plug module is attached to the engine with two screws It is installed directly to the spark plug by an electrical contact inside a rubber boot A three way connector pr...

Страница 1442: ...he ignition coil receives the 5 volt signal from the PCM it provides a ground path for the B supply to the primary side of the coil at plug module When the PCM shuts off the 5 volt signal to the ION s...

Страница 1443: ...re not burned off Very rich fuel mixtures or poor ignition system output may also be the cause Refer to DTC P0172 Oil fouling of the spark plug is indicated by wet oily deposits on the portion of the...

Страница 1444: ...g replace it Spark plugs with cracked or broken insulators should always be replaced A C Clutch Diagnosis A C Clutch Circuit Operation A 12 volt signal is supplied to the A C request input of the PCM...

Страница 1445: ...he IAT reading is above 10 C 50 F A continuous purge condition with no purge commanded by the PCM will set a DTC P1441 Poor idle stalling and poor driveability can be caused by D A malfunctioning purg...

Страница 1446: ...P sensor However the fuel tank pressure sensor has very different electrical characteristics due to its pressure differential design The sensor measures the difference between the air pressure or vacu...

Страница 1447: ...r leak testing 014RW148 D Fuel Level Sensor The fuel level sensor is an important input to the PCM for the enhanced EVAP system diagnostic The PCM needs fuel level information to know the volume of fu...

Страница 1448: ...nected or faulty EVAP vent solenoid D Open ignition feed circuit to the EVAP vent or purge solenoid D Damaged EVAP canister D Leaking fuel sender assembly O ring D Leaking fuel tank or fuel filler nec...

Страница 1449: ...tion D Above idle speed Too much EGR flow at idle cruise or cold operation may cause any of the following conditions to occur D Engine stalls after a cold start D Engine stalls at idle after decelerat...

Страница 1450: ...he crankcase These gases are mixed with clean air entering through a tube from the air intake duct 028RW002 During normal part throttle operation the system is designed to allow crankcase gases to flo...

Страница 1451: ...r 4 DLC Cable 5 TECH 2 J 34142 B Unpowered Test Light Connector Test Adapter Kit J 35616 A BT 8637 J 26792 BT 7220 1 Spark Tester J 34730 E Port Fuel Injection Diagnostic Kit ILLUSTRATION TOOL NO TOOL...

Страница 1452: ...413 EVAP Pressure Purge Diagnostic System Small leaks in the EVAP system will emit sound at a high frequency undetectable by a human ear but detectable with the J 41416 The technician traces along the...

Страница 1453: ...ion 6F 3 Three Way Catalytic Converter LH 6F 4 Removal 6F 4 Installation 6F 4 Three Way Catalytic Converter RH 6F 5 Removal 6F 5 Installation 6F 5 Exhaust Silencer 6F 6 Exhaust Silencer and Associated...

Страница 1454: ...and rubber blocks The installation of exhaust system supports is very important as improperly installed supports can cause annoying vibrations which can be difficult to diagnose Three Way Catalytic C...

Страница 1455: ...Sensor Terminal Connector 10 Front Exhaust Pipe RH Removal 1 Disconnect battery ground cable 2 Raise the vehicle and support with suitable safety stands 3 Disconnect O2 sensor harness connector 2 5 7...

Страница 1456: ...ifold side and two nuts 4 5 from rear end of exhaust front pipe 6 150RW013 Legend 1 Front Exhaust Pipe Fixing Three Stud Nuts 2 O2 Sensor Harness Connector 3 O2 Sensor Harness Connector 4 Front Exhaus...

Страница 1457: ...ud nuts 1 from exhaust manifold then remove the exhaust front pipe 5 150RW010 Legend 1 Front Exhaust Pipe Fixing Three Stud Nuts 2 O2 Sensor Harness Connector 3 Front Exhaust Pipe Fixing Bolts and Nut...

Страница 1458: ...exhaust pipe from exhaust silencer 4 Remove exhaust silencer fixing bolts 4 then disconnect exhaust silencer from front exhaust pipe 5 5 Remove exhaust silencer mounting nuts from chassis side then r...

Страница 1459: ...ery ground cable 2 Raise the vehicle and support with suitable safety stands 3 Remove rear exhaust pipe fixing nuts 3 then disconnect rear exhaust pipe from exhaust silencer 4 Remove mounting rubber 1...

Страница 1460: ...6F 8 ENGINE EXHAUST Main Data and Specifications Torque Specifications E06RW022...

Страница 1461: ...R NEAR THE SRS COMPONENTS OR THE SRS WIRING REFER TO THE SRS SERVICE INFORMATION FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT PERSONAL INJURY OR OTHERWISE UNNEEDED SRS SYSTEM...

Страница 1462: ...essure Switch 5 Oil Filter 6 Safety Valve 7 Oil Pressure Unit 8 Oil Gallery 9 Crankshaft Bearing 10 Crankshaft 11 Connecting Rod Bearing 12 Connecting Rod 13 Piston 14 Oil Gallery Cylinder Head 15 Cam...

Страница 1463: ...Assembly 6 Plug 7 Spring 8 Relief Valve 9 Oil Pump Cover 10 Driven Gear 11 Drive Gear 12 Oil Seal 13 O ring 14 Oil Pump Body Disassembly 1 Remove crankshaft timing pulley 2 Remove crankcase with oil p...

Страница 1464: ...ced if one or more of the conditions below is discovered during inspection D Badly worn or damaged driven gear 10 D Badly worn drive gear 11 driving face D Badly scratched or scored body sliding face...

Страница 1465: ...ring 7 5 Install spring 7 6 Install the plug 6 Torque 8 N m 69 lb in 051RS007 7 Install oil pump assembly 5 D Carefully remove any oil from the cylinder body and the pump Apply sealant TB 1207B or equ...

Страница 1466: ...oil pipe 3 with O ring 13 Torque 25 N m 18 lb ft 11 Install crankcase with oil pan 2 D Remove oil on crankcase mounting surface and dry the surface D Apply a proper 4 5 mm 0 7 in wide bead of sealant...

Страница 1467: ...heel side At this time support the axle with a garage jack and remove axle housing assembly For 4 4 11 Remove starter fixing bolts 12 Remove oil pan fixing bolts 13 Remove oil pan using J 37228 sealer...

Страница 1468: ...fter sealant application befor the sealant hardens 013RW003 3 Install oil pan tighten oil pan fixing bolts to the specified torque Torque 25 N m 18 lb ft 3 Install starter and tighten fixing bolts Tor...

Страница 1469: ...s member and tighten fixing bolts to the specified torque Torque 78 N m 58 lb ft 013RW007 8 Install radiator under fan shroud 9 Install under cover 10 Install engine oil level dipstick 11 Fill engine...

Страница 1470: ...bly cylinder block and take care not to damage mounting surfaces of oil pump and cylinder block Installation 1 Install oil pump assembly D Apply sealant TB 1207B or equivalent to the oil pump mounting...

Страница 1471: ...To Oil Filter 5 Install timing pulley on crankshaft Install timing belt D Refer to installation procedure for Timing Belt in this manual 6 Install crankshaft pulley D Refer to install procedure for Cr...

Страница 1472: ...oil pump oil seal using a sealer puller NOTE Take care not to damage sealing surfaces of oil pump and crankshaft when removing oil seal Installation 1 Install oil pump oil seal apply engine oil to oil...

Страница 1473: ...surface and apply small amount of engine oil to sealing surface 2 Install oil filter cartridge by hand until it comes in contact with sealing surface then rotate additional 2 3 turn to tighten using J...

Страница 1474: ...a and Specification General Specification Item Specifications Item 6VE1 Oil capacity 5 3 liters Torque Specifications Crankcase Oil pan Timing belt tensioner Timing pulley timing belt cover Oil pump O...

Страница 1475: ...AIR BAG DEPLOYMENT PERSONAL INJURY OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS CAUTION Always use the correct fastener in the proper location When you replace a fastener use ONLY the exact part number fo...

Страница 1476: ...n Sensor 2 Accelerator Pedal Assembly Removal 1 Disconnect battery ground cable 2 Disconnect Accelerator position AP sensor 1 connector from Accelerator pedal assembly 3 Remove Accelerator pedal assem...

Страница 1477: ...URY OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS CAUTION Always use the correct fastener in the proper location When you replace a fastener use ONLY the exact part number for that application ISUZU will c...

Страница 1478: ...damaged or clean if it is clogged Cleaning Method Tap the air cleaner filter gently so as not to damage the paper filter or clean the element by blowing with compressed air of about 490 kPa 71 psi fro...

Страница 1479: ...th Transfer Case Extension Assembly 7A 31 Transmission And Associated Parts 7A 31 Removal 7A 32 Installation 7A 33 Solenoid Main Case Valve Body 7A 38 Removal 7A 38 Installation 7A 38 Solenoid Adapter...

Страница 1480: ...embly 7A 72 Inspection And Repair 7A 73 Reassembly 7A 73 Reverse Clutch Piston And Center Support 7A 74 Disassembled View 7A 74 Disassembly 7A 74 Inspection And Repair 7A 75 Reassembly 7A 75 Overrun C...

Страница 1481: ...hose fasteners that require a replacement after removal ISUZU will also call out the fasteners that require thread lockers or thread sealant UNLESS OTHERWISE SPECIFIED do not use supplemental coatings...

Страница 1482: ...7A 4 AUTOMATIC TRANSMISSION 4L30 E Range Reference Chart C07RY00032...

Страница 1483: ...Lock Out With the selector lever in reverse position the PCM will not close the PWM solenoid until the vehicle is below 11 km h 6 8 mph thus preventing reverse engagement above this speed Diagnosis In...

Страница 1484: ...7A 6 AUTOMATIC TRANSMISSION 4L30 E F07RT036 Example of form completed...

Страница 1485: ...7A 7 AUTOMATIC TRANSMISSION 4L30 E F07RT037...

Страница 1486: ...7A 8 AUTOMATIC TRANSMISSION 4L30 E General Diagnosis Procedure F07RT038...

Страница 1487: ...7A 9 AUTOMATIC TRANSMISSION 4L30 E Preliminary Inspection Chart F07RY00001...

Страница 1488: ...ng brake firmly 2 Check fluid level with engine running at idle NOTE Be sure that transmission fluid temperature is below 30 C 86 F 3 Move the selector lever through all gear ranges 4 Move the selecto...

Страница 1489: ...rom the areas being monitored for use in diagnosis Also listen for and note any unusual noises The following procedure should be used to test drive 4L30 E automatic transmission complaint vehicles 1 T...

Страница 1490: ...at a problem related to the transmission the Powertrain Control Module PCM or the vehicle harness has occurred The system is now operating in a BACKUP MODE where the risk of further damaging the trans...

Страница 1491: ...2 OR 2 3 SHIFT 13 SHUDDER ONLY DURING TORQUE CONVERTER CLUTCH TCC APPLYING 14 POSSIBLE CAUSES OF TRANSMISSION NOISE 15a POSSIBLE CAUSES OF LOW LINE PRESSURE 15b POSSIBLE CAUSES OF HIGH LINE PRESSURE...

Страница 1492: ...n roller clutch 516 broken loose Was the problem found Repair or replace Chart 3 No Engine Brake In Any Range Step Action Yes No 1 Check line pressure Refer to Line Pressure Test in this section Was l...

Страница 1493: ...05 set Diagnose those DTC s first Use Chart 15b Possible Causes of High Line Pressure in this section Chart 5a Delays In Drive And Reverse NOTE A short delay less than 3 seconds when first engaging dr...

Страница 1494: ...lenoid A stuck Replace shift solenoid A 4 DTC P0730 is set in D range 1st gear above 3500 rpm Go to Step 3 5 DTC P0730 is set in D range 3rd gear between 55 80 mph NOTE Perform this test within safe a...

Страница 1495: ...stuck in adapter case valve body 401 2 Check for 3 4 accumulator piston 18 stuck in adapter case 20 Was the problem found Repair or replace Chart 9a 3 2 Downshift Complaint Step Action Yes No 1 Check...

Страница 1496: ...ng harness damage or short to ground If OK go to 2 2 Check transmission speed sensor connections If OK go to 3 3 Replace transmission speed sensor Was the replacement complete Replace speed sensor Cha...

Страница 1497: ...d flush cooler lines Replace converter assembly and O ring on turbine shaft Perform mechanical inspection of other drivetrain components Chart 14 Possible Causes Of Transmission Noise CAUTION Before c...

Страница 1498: ...blem found Replace feed limit valve 412 Go to Step 6 6 Check for loose converter bolts 4 5 Was the problem found Tighten converter bolts 4 5 Go to Step 7 7 Check for a stuck pressure regulator valve 2...

Страница 1499: ...ck for a stuck feed limit valve 412 Adapter case valve body Was the problem found Replace force motor plunger 412 Go to Step 4 4 Check converter bolts 4 5 Was the problem found Tighten converter bolts...

Страница 1500: ...hould be made 1 With the engine running check for external line pressure leaks 2 With the engine off check for oil leaks due to the raised oil level caused by drainback of converter oil into the trans...

Страница 1501: ...checks oil pump and control valve pressure regulator valve function It will also detect oil leakage Line Pressure Test Procedure 1 Check the level of the engine coolant the engine oil and the automati...

Страница 1502: ...rth Gear km h mph D Fully opened 53 59 33 37 110 116 68 72 166 172 103 107 Drive Half throttle 32 38 20 24 57 63 35 39 99 105 61 65 3 Fully opened 53 59 33 37 110 116 68 72 Third Half throttle 32 38 2...

Страница 1503: ...wnshift Range Throttle opening 1 2 First Gear Second Gear km h mph 2 3 Second Gear Third Gear km h mph 3 4 Third Gear Fourth Gear km h mph D Fully opened 45 51 28 32 104 110 65 68 163 169 101 105 D Dr...

Страница 1504: ...4 300 ECCC Apply ECCC Release D range Throttle i 6 Mode 2nd Km h mph 3rd Km h mph 4th Km h mph 2nd Km h mph 3rd Km h mph 4th Km h mph opening 6 Normal 57 63 35 39 42 48 26 30 43 49 27 31 52 58 32 36...

Страница 1505: ...is reached 6 Add transmission fluid until it flows out over the overfill screw opening then close the overfill screw 1 Torque 38 N m 28 lb ft NOTE To prevent fluid leaks the overfill screw and oil dr...

Страница 1506: ...orward R position side and secure it using a rubber band 3 etc so that the pin comes into contact with the wall of the detent plate 5 Install the shift control rod 1 to the selector lever arm 4 Torque...

Страница 1507: ...Remove bracket with mode switch connector from the transmission case 7 Remove mode switch connector 3 from the bracket 4 8 Remove two mode switch bolts and nut then remove mode switch 5 210RW008 Insta...

Страница 1508: ...istance mode to terminals 1 E and 4 H on mode switch connector e Loosen two mounting screws f Rotate mode switch slightly in both directions to determine the range approx 5 degrees of electrical conta...

Страница 1509: ...Lever 4 4 5 Transfer Protector 4 4 6 Rear Propeller Shaft 7 Front Propeller Shaft 4 4 8 Harness Protector 9 Rear Mount Nut 10 Third Crossmember 11 Left Catalytic Converter Assembly 12 Seat Belt Tensio...

Страница 1510: ...ide 12 Remove eight third crossmember bolts and third crossmember 10 13 Remove front exhaust silencer mounting nuts 14 Remove left seat belt tension rod 15 Disconnect two left side oxygen sensor conne...

Страница 1511: ...y from the transmission assembly if necessary Installation 1 Slowly raise transmission jack until front of the transmission is aligned with rear of the engine then install transmission assembly 2 Tigh...

Страница 1512: ...8 N m 69 lb in 6 Install front crossmember Torque 78 N m 58 lb ft 7 Install the starter and tighten the bolts to the specified torque Torque 40 N m 30 lb ft 8 Connect transmission harness connectors t...

Страница 1513: ...7A 35 AUTOMATIC TRANSMISSION 4L30 E For 4 4 141RW027...

Страница 1514: ...onverter assembly and tighten the bolts to the specified torque Exh pipe to exh manifold 67 N m 49 lb ft Exh pipe flange bolt 43 N m 32 lb ft 15 Install left seat belt tension rod Torque 39 N m 29 lb...

Страница 1515: ...orque 63 N m 46 lb ft 24 Connect the shift control rod to selector lever assembly 25 Install the transfer protectors and tighten the bolts to the specified torque 4 4 Torque 37 N m 27 lb ft 26 Install...

Страница 1516: ...e solenoids by grasping the metal tip Installation 1 Install shift solenoid A shift solenoid B band control solenoid with new gaskets to main case valve body respectively 2 Carefully install spring pi...

Страница 1517: ...PWM solenoid with two O rings 210RY001 7 Remove 11 mm bolt retainer and force motor solenoid 210RW009 Installation 1 Install force motor solenoid retainer and 11 mm bolt to adapter case valve body Tig...

Страница 1518: ...install main case D Install valve body assembly and manual valve link NOTE Valve must be extended as the short end of manual valve link is connected to the range selector lever Long end of link goes...

Страница 1519: ...ical 4 way connector and seal of adapter case Replace if necessary 2 Install gasket transfer plate and gasket 3 Install adapter case valve body and seven 13 mm screws Tighten the screws to the specifi...

Страница 1520: ...ift lock cable Refer to Selector Lever in this section 5 Install front console 6 Connect battery ground cable Transmission Oil Temperature Sensor Main Case Removal 1 Raise the vehicle and support it o...

Страница 1521: ...ue converter from converter housing 3 Remove three screws and oil seal ring from converter housing 241RW008 Installation 1 Apply clean ATF to the new oil seal ring lip D Install oil seal ring to conve...

Страница 1522: ...shaft 3 Remove two 10mm mode switch screws selector lever nut cover and mode switch 3 4 Remove twelve 10mm adapter case oil pan 4 fixing screws adapter oil pan and gasket 5 Disconnect electrical wiri...

Страница 1523: ...mission to vertical position to drain fluid Return back to horizontal position when drained D Install J 23075 servo piston spring compressor with offset to the rear of case D Compress servo piston ass...

Страница 1524: ...xtension housing assembly 19 and gasket 18 Remove retaining ring 20 NOTE Use extra long needle nose pliers 19 Remove speed wheel 21 20 Remove wheel parking lock with seal ring 22 241RS002 21 Rotate tr...

Страница 1525: ...thrust washer 34 and two O ring seals 35 from main case 32 Use J 23327 and J 23327 90 compressor to compress the fourth clutch spring retainer and springs 37 D Release snap ring 36 from groove D Remo...

Страница 1526: ...uring removal Be aware of pin height Protect machined face of main case 48 Remove parking lock and range selector lever 17 mm nut 57 49 Remove parking lock and range selector lever 56 and actuator ass...

Страница 1527: ...ate the master tooth space and exactly opposite with a single point to indicate the master tooth The markings on the planetary carrier consist of double lines which are to be lined up with the double...

Страница 1528: ...thrust washer in place 17 Install third clutch and intermediate shaft assembly 13 into the second clutch drum 14 18 Install second and third clutch assemblies into the main case Twist output shaft an...

Страница 1529: ...select the appropriate washer as shown in the chart Selective Thrust Washer Gap mm in Color 1 53 1 63 0 060 0 064 Yellow 1 72 1 82 0 068 0 072 Red 1 91 2 01 0 075 0 079 Black 2 10 2 20 0 083 0 087 Na...

Страница 1530: ...J 38588 guide pins D Install adapter case and center support assembly to main case 242RS004 29 Install thrust washer 26 into adapter case with tangs pointing downwards 30 Preassemble overdrive intern...

Страница 1531: ...appropriate size washer as shown in the chart 5 Set selective thrust washer aside Selective Thrust Washer Gap mm in Color 1 53 1 63 0 060 0 064 Yellow 1 72 1 82 0 068 0 072 Red 1 91 2 01 0 075 0 079...

Страница 1532: ...NOTE If end play is not correct repeat selective washer selection 252RW001 39 Inspect extension housing oil seal and replace if necessary using J 36797 extension housing oil seal installer D Rotate tr...

Страница 1533: ...sitioned Rotate output shaft if necessary D Install J 38428 servo piston fitter in servo bore D Install apply rod 40 round end toward band return spring 41 and piston assembly 42 45 Install the J 2307...

Страница 1534: ...main oil pan 50 and sixteen 10 mm screws Torque 11 N m 96 lb in 54 Inspect adapter case electrical connector and seal Replace if necessary D Install electrical five pin connector and harness assembly...

Страница 1535: ...e in stator g Contamination from engine coolant h Excess end play D Rotate transmission bell housing up Spin converter to insure proper fit 61 Fill transmission through the overfill screw hole of oil...

Страница 1536: ...eck If any damage deformation or local wear is found in a converter housing outer seal ring wear plate or oil seal ring replace it Reassembly 1 Install wear plate onto oil pump assembly 2 Install conv...

Страница 1537: ...ignal Accumulator Piston 22 Sleeve Pin 23 Boost Valve Sleeve 24 Boost Valve 25 Spring Seat 26 Pressure Regulator Valve Spring 27 Spring Seat 28 Pressure Regulator Valve 29 Oil Pump Assembly Disassembl...

Страница 1538: ...sembly 29 3 Assemble boost valve 24 into sleeve 23 4 Install boost valve and sleeve assembly and sleeve pin 22 to oil pump assembly 29 5 Install throttle signal accumulator piston 21 spring 20 and spr...

Страница 1539: ...5 1 2 Accumulator Valve 26 1 2 Accumulator Control Valve 27 Check Ball 28 Main Case Valve Body Disassembly 1 Remove two 11mm bolts from valve body 28 then remove gaskets and transfer plate 1 2 Remove...

Страница 1540: ...erations 5 Spring fatigue Reassembly 1 Install 1 2 accumulator control valve 26 1 2 accumulator valve 25 plug 24 and spring pin 23 2 Install band control screen assembly 22 plug 21 and spring pin 20 3...

Страница 1541: ...r clutch PWM solenoid 2 2 Remove 11mm bolt and retainer 3 from valve body D Remove force motor solenoid 4 3 Remove retainer 5 plug 6 3 4 accumulator valve 7 and 3 4 accumulator control valve 8 4 Remov...

Страница 1542: ...rol valve 8 3 4 accumulator valve 7 plug 6 and retainer 5 4 Install force motor solenoid 4 D Place solenoid terminals pointing towards mating face D Install retainer 3 and bolt Torque 10 N m 87 lb in...

Страница 1543: ...d of the depressor handle provided with the tool J 38450 A Slide one blade down between the third clutch drum and the retaining ring 3 Remove a screwdriver and repeat this step for the other end of re...

Страница 1544: ...ing 4 and retaining washer 3 5 Fully engage the hub splines of the input sun gear and sprag unit assembly 2 into the third clutch inner tangs D Simultaneously rotate the outer sprag race to engage int...

Страница 1545: ...groove D Remove spring seat 2 and springs 3 3 Remove piston assembly 4 from third clutch drum 5 Inspection And Repair Visual check If any damage deformation or wear is found replace the damaged part...

Страница 1546: ...at D Compress the piston springs using the J 23075 piston spring compressor and J 23075 12 adapter CAUTION Do not over stress the springs and seat Do not let the spring seat catch in the ring groove T...

Страница 1547: ...r of the sprag cage faces the sun gear This procedure must be followed exactly to be sure that the sprag assembly is installed properly 1 Install rings and sprag assembly onto the third clutch hub and...

Страница 1548: ...ing Seat 9 Springs 10 Piston Assembly 11 Second Clutch Drum Disassembly 1 Remove retaining ring 1 from second clutch drum 11 2 Remove ring gear 2 retaining ring 3 and spacer 4 3 Remove clutch plates 5...

Страница 1549: ...h piston installer to protect the outer piston lip seal NOTE Lip of the seal should point toward front of transmission D Remove the installer 247RS007 2 Install twenty two piston springs 9 and spring...

Страница 1550: ...ing 4 Piston Assembly Disassembly 1 Install the J 38559 A cover compressor on adapter case D Compress piston cover then remove snap ring 242RS007 2 Install the J 41096 cover remover and J 38584 adapte...

Страница 1551: ...damaged part Reassembly 1 Place the J 38553 piston fitter into adaptor case and push the piston into position using suitable diameter tube D Remove the piston fitter 244RS006 2 Install spring and cove...

Страница 1552: ...fer Plate 8 Gasket 9 Restrictor 10 Retainer Plate 11 Plug 12 Spring 13 Overrun Lock Out Valve 14 Retainer Plate 15 Plug 16 Spring 17 Reverse Lock Out Control Valve Disassembly 1 Install the J 23327 co...

Страница 1553: ...lve 17 and spring 16 to center support NOTE Ensure correct assembly of valve The spring should be located over the long small diameter end 2 Install plug 15 and retainer plate 14 3 Install overrun loc...

Страница 1554: ...nap Ring 2 Overdrive Carrier Assembly 3 Sun Gear 4 Turbine Shaft 5 Snap Ring 6 Backing Plate 7 Clutch Plates 8 Snap Ring 9 Overrun Roller Clutch Cam 10 Roller Clutch Assembly 11 Overrun Clutch Release...

Страница 1555: ...oller clutch cam 9 and roller clutch assembly 10 6 Remove overrun clutch release spring retainer 11 and diaphragm spring 12 7 Remove piston assembly 13 from overrun clutch drum 14 8 Remove turbine sha...

Страница 1556: ...e snap ring loosely on spring retainer D Hold the J 23327 91 compressor in a vise and compress piston return spring with compressor D Set snap ring 8 in ring groove D Remove the compressor 6 Install c...

Страница 1557: ...t Noiseless high torque capability Oil used Name ATF DEXRON III Oil used Q ty liter qt 8 6 9 1 Torque converter 2 100 150 Stall speed rpm Reverse clutch RC 4 Second clutch C2 6 Number of discs Third c...

Страница 1558: ...7A 80 AUTOMATIC TRANSMISSION 4L30 E Torque Specifications E07RY00013...

Страница 1559: ...7A 81 AUTOMATIC TRANSMISSION 4L30 E E07RY003...

Страница 1560: ...7A 82 AUTOMATIC TRANSMISSION 4L30 E E07RY001...

Страница 1561: ...with J 23075 J 23084 Third clutch piston installer J 23327 Third clutch spring compressor J 23080 A Second clutch piston installer ILLUSTRATION TOOL NO TOOL NAME J 23085 A Selective washer gauging to...

Страница 1562: ...to valve body J 25022 Turbine shaft puller Use with J 24773 1 J 23129 Oil seal remover Use with J 23907 and J 38584 J 38557 Oil pump centering tool ILLUSTRATION TOOL NO TOOL NAME J 23082 01 Oil pump...

Страница 1563: ...ISSION 4L30 E ILLUSTRATION TOOL NO TOOL NAME J 36797 A T extension housing oil seal installer Inside J 3289 20 Holding fixture base J 29770 A Pressure gauge J 24773 1 End play fixture Use with J 25022...

Страница 1564: ...11 Gasket 12 Washer Thrust Selective 13 Ring Snap 14 Cover 3 4 Accumulator Piston 15 Seal O Ring 3 4 Accumulator 16 Spring 3 4 Accumulator Piston 17 Pin 3 4 Accumulator Piston 18 Piston 3 4 Accumulat...

Страница 1565: ...ter Case 72 Gasket Adapter Valve Body 73 Plate Adapter Valve Body Transfer 74 Pan Bottom Main Case 75 Gasket Bottom Pan Main Case 76 Gasket Oil Drain or Overfill Screw 77 Screw Oil Drain or Overfill 7...

Страница 1566: ...Signal Accumulator 210 Piston Throttle Signal Accumulator 211 Pin Boost Valve Sleeve 212 Sleeve Boost Valve 213 Valve Boost 214 Seat Spring Pressure Regulator Valve 215 Spring Pressure Regulator Valve...

Страница 1567: ...306 Retainer Valve 307 Solenoid Assembly ON OFF N O 308 Valve 2 3 Shift 309 Pin Spring 310 Plug Valve Bore 311 Spring Valve Low Pressure Control 312 Valve Low Pressure Control 317 Ball Check 318 Valv...

Страница 1568: ...Motor 405 Plug 3 4 Accumulator 406 Plug and Spring Retainer 407 Valve 3 4 Accumulator 409 Valve 3 4 Accumulator Control 410 Spring Feed Limit Valve 411 Ring Retainer 412 Valve Feed Limit 413 Seal O R...

Страница 1569: ...r Assembly Overdrive Clutch 517 Cam Overdrive Roller Clutch 518 Ring Snap Overrun Clutch Hub 519 Gear Overdrive Sun 520 Plate Waved Overrun Clutch 521 Plate Overrun Clutch Steel 522 Plate Assembly Ove...

Страница 1570: ...nner 621 Seal 2nd Clutch Piston Outer 622 Piston 2nd Clutch 623 Seat Spring 2nd Clutch 625 Plate Waved 2nd Clutch 626 Plate 2nd Clutch Steel 627 Plate Assembly 2nd Clutch Lined 628 Spacer 2nd Clutch 6...

Страница 1571: ...Shaft Input Sun 653 Carrier Assembly Planetary 658 Gear Reaction Sun 659 Drum Reaction Sun 664 Band Assembly Brake 667 Seal Ring Wheel Parking Lock 668 Wheel Parking Lock 672 Wheel Speed 673 Ring Ret...

Страница 1572: ...ng assembly 2 Remove end nut and companion flange 2 using the companion flange holder J 8614 11 266RW001 3 Use the universal puller to remove the companion flange and O ring 4 Remove the oil seal from...

Страница 1573: ...ten to the specified torque Torque 167 N m 123 lb ft 6 Use the punch J 39209 to stake the end nut at two spots NOTE Be sure to confirm that there is no crack at the staked portion of the end nut 2 aft...

Страница 1574: ...7A 96 AUTOMATIC TRANSMISSION 4L30 E Extension Housing Assembly Extension Housing Assembly and Associated Parts 260RY00006 Legend 1 Propeller Shaft 2 Mass 3 Extension Housing Assembly...

Страница 1575: ...ensor 4 Removing the speedometer driven gear bushing and driven gear drain extension housing assembly fluid 5 Remove propeller shaft 1 and mass 2 NOTE Apply alignment marks on the flange at both front...

Страница 1576: ...ng assembly bolts as shown in the figure 261RY00001 3 Install speedometer driven gear bushing and driver gear 4 Connect harness connectors and fuel pipe fix bolt Connector speed sensor 5 Install prope...

Страница 1577: ...TRANSMISSION 4L30 E Extension Housing Assembly Extension Housing Assembly and Associated Parts 220RY00009 Legend 1 Speedometer Sensor Speedometer Driven Gear and Plate 2 Companion Flange 3 Extension H...

Страница 1578: ...on holder J 8614 11 to remove the end nut 266RW001 5 Remove the rear companion flange NOTE Use the universal puller to remove the rear companion flange Installation 1 Install companion flange 2 using...

Страница 1579: ...Install the driven gear to the speedometer driven gear bushing 6 6 Install the speedometer driven gear assembly to the extension housing assembly 7 Install the plate 5 to the extension housing assembl...

Страница 1580: ...Extension Housing Assembly 220RY00011 Legend 1 Bearing Snap Ring 2 Front Ball Bearing 3 Extension Shaft 4 Bearing Snap Ring 5 Front Oil Seal 6 Ball 7 Speedometer Drive Gear 8 Rear Ball Bearing 9 Air B...

Страница 1581: ...ss and bearing remover J 22912 01 220RY00007 9 Remove air breather pipe collar 9 from the extension housing assembly Reassembly 1 Install air breather pipe collar 9 to the extension housing assembly C...

Страница 1582: ...the surfaces of every part Apply compressed air to each oil feed port and channel in each case half to remove any obstructions or cleaning solvent residue Bearings 1 Inspect the condition of all bear...

Страница 1583: ...7A 105 AUTOMATIC TRANSMISSION 4L30 E Main Data and Specifications General Specifications Oil capacity 0 185 lit 0 195 U S quart Type of lubricant ATF DEXRON III Torque Specifications 220RY00012...

Страница 1584: ...7A 106 AUTOMATIC TRANSMISSION 4L30 E Special Tools ILLUSTRATION PART NO PART NAME J 22912 01 Bearing remover installer J 39209 Punch end nut J 39208 Rear oil seal installer J 8614 11 Flange holder...

Страница 1585: ...ntification 7A1 23 Isuzu Trooper 7A1 23 Diagnostic Trouble Code DTC Identification 7A1 24 DTC P0218 Transmission Fluid Over Temperature 7A1 25 DTC P0705 Transmission Range Switch Mode Switch Illegal P...

Страница 1586: ...l Description The 4L30 E is a 4 speed fully automatic transmission It uses a microcomputer as a control unit to judge running conditions including throttle opening rate and vehicle speed then it sets...

Страница 1587: ...TRANSMISSION CONTROL SYSTEM 4L30 E 7A1 3 Electronic Control Diagram C07RY00034...

Страница 1588: ...7A1 4 TRANSMISSION CONTROL SYSTEM 4L30 E Powertrain Control Module PCM C07RY002...

Страница 1589: ...TRANSMISSION CONTROL SYSTEM 4L30 E 7A1 5 Control System Diagram C07RY00033...

Страница 1590: ...ion Fail Safe Mechanism If there is a problem in the transmission system the PCM will go into a backup mode The vehicle can still be driven but the driver must use the select lever to shift gears Torq...

Страница 1591: ...TRANSMISSION CONTROL SYSTEM 4L30 E 7A1 7 Shift Mode Control F07RX001...

Страница 1592: ...7A1 8 TRANSMISSION CONTROL SYSTEM 4L30 E Gear Shift Control F07RT034...

Страница 1593: ...tion a When vehicle runs at 21mph 34 km h or more for 1 second or more b When transmission oil temperature reaches 130 C 266 F or above NOTE The mode returns to normal drive mode or power drive mode a...

Страница 1594: ...r has been switched on or not and feeds the information to PCM Winter switch fixed to front console Senses whether the driver has selected the winter mode and feeds the information to PCM Cruise contr...

Страница 1595: ...agrams Check Trans Indicator Find CHECK TRANS indicator and verify if it is A Flashing GOTO DIAGNOSTIC CHECK B Staying on GOTHROUGH CHECK TRANS CHECK C Is never ON when the ignition key is turned on G...

Страница 1596: ...TOD or 6 WO TOD of connector I 9 is shorted to ground 3 Verify if the PCM connector J2 RED terminal 46 is shorted to ground 4 Verify that the instrument panel terminal 15 WO TOD or 26 W TOD of connect...

Страница 1597: ...I Connection In order to access OBD II Powertrain Control Module PCM data use of the Tech 2 scan tool kit 7000086 is required 1 The electronic diagnosis equipment is composed of 1 Tech 2 hand held sca...

Страница 1598: ...E 16 19 Adapter 4 DLC Cable 5 Tech 2 D Before operating the Isuzu PCMCIA card with the Tech 2 the following steps must be performed 1 The Isuzu 2000 System PCMCIA card 1 inserts into the Tech 2 5 2 Co...

Страница 1599: ...ignition turns on 7 Verify the Tech 2 power up display 060RW009 NOTE The RS232 Loop back connector is only to use for diagnosis of Tech 2 and refer to user guide of the Tech 2 8 The power up screen i...

Страница 1600: ...s F0 Diagnostic Trouble Codes F0 Read DTC Info Ordered By Priority F1 Clear DTC Information F2 DTC Information F1 Data Display F0 Transmission Data F1 Output Driver Data F2 Snap Shot F3 Actuator Tests...

Страница 1601: ...Transmission Data on next page Snapshot When Snapshot is selected an Application Menu appears When Transmission Snapshot application is selected from the Application Menu a Snapshot Menu appears disp...

Страница 1602: ...Gear 1 Current Gear 1 Mode Switch A Inactive Active Active Mode Switch B Inactive Active Inactive Mode Switch C Inactive Active Inactive Mode Switch G Inactive Active Active Selector Position Park 1...

Страница 1603: ...AE J1850 recommended practice for serial data Serial Data refers to information which is transferred in a linear fashion over a single line one bit at a time A Data Bus is an electronic pathway throug...

Страница 1604: ...means that if two devices try to communication on the data line at the same time only the higher priority message will continue The device with the lower priority message must wait NOTE The Class 2 da...

Страница 1605: ...Will store the DTC and turn on the MIL on the second consecutive trip in which an emission related diagnostic test has run and reported a test failed to the Diagnostic Executive After one failure the...

Страница 1606: ...ition or while walking some distance Information On PCM 1 The Powertrain Control Module PCM is located in the center console and is the control center of the electronic transmission control system 2 T...

Страница 1607: ...jump in data values out of the normal range Transmission And PCM Identification The chart below contains a list of all important information concerning rear axle ratio Powertrain Control Module PCM a...

Страница 1608: ...Clutch TCC System Stuck ON B ON Flash P0748 Pressure Control Solenoid PCS Force Motor Circuit Electrical C Flash P0751 Shift Solenoid A Performance Stuck OFF B ON Flash P0752 Shift Solenoid A Perform...

Страница 1609: ...e vehicle has achieved 40 warm up cycles without a failure reported D The PCM will cancel the DTC default actions when the fault no longer exists and the ignition is cycled off long enough to power do...

Страница 1610: ...function is used 3 Record the DTC Failure Records Is the TFT sensor signal voltage less than 0 33 volts Go to Step 4 Go to Diagnostic Aids 4 1 Turn the ignition off 2 Disconnect the transmission 16 w...

Страница 1611: ...positions met for 5 seconds Action Taken When The DTC Sets D Default to D position D Inhibit torque management D Maximum line pressure D Turn force motor OFF D The PCM will not illuminate the Malfunc...

Страница 1612: ...l to the manual valve actually selected 6 This test checks for continuity between each selected range switch connector terminals Range Switch Logic Table Range Range Switch Pin g Position A B C P G Pa...

Страница 1613: ...ge switch pin displays incorrect Go to Step 5 Go to Step 6 5 Check fuse and wiring to the 8 way connector terminal 5 D for opens Refer to Mode Switch in Automatic Transmission 4L30 E section If no pro...

Страница 1614: ...his DTC detects an invalid state of the range switch or the range switch circuit by deciphering the range switch inputs This is a type D DTC Conditions For Setting The DTC This DTC will set if any of...

Страница 1615: ...ossible intermittent short or open condition move the wiring harness while observing test equipment for a change D Refer to the Range Switch Logic Table or Functional Test Procedure for further inform...

Страница 1616: ...switch pin displays incorrect Go to Step 5 Go to Step 6 5 Check fuse and wiring to the 8 way connector terminal 5 D for opens Refer to Mode Switch in Automatic Transmission 4L30 E section If no probl...

Страница 1617: ...eater than 120 rpm for greater than 410 seconds since engine startup cumulative timer D Battery voltage is between 10 and 16 volts All of the above is true and either of the following occurs D If the...

Страница 1618: ...Condition in Automatic Transmission 4L30 E section 3 1 Install the scan tool 2 With the engine off turn the ignition switch to the on position NOTE Before clearing DTCs use the scan tool in order to...

Страница 1619: ...tep 10 9 Replace the automatic transmission wiring harness assembly Is the replacement complete Go to Step 12 10 Replace TFT Sensor Refer to Transmission Oil Temperature Sensor Main Case in Automatic...

Страница 1620: ...ons For Clearing The DTC D The DTC can be cleared from the PCM history by using a scan tool D The DTC will be cleared from history when the vehicle has achieved 40 warmup cycles without a failure repo...

Страница 1621: ...reference as data will be lost when the Clear Info function is used 3 Record the DTC Freeze Frame and Failure Records Does the scan tool display a TFT sensor signal voltage less than 0 4 volts Go to...

Страница 1622: ...ground Was a problem found Go to Step 13 Go to Step 11 11 Check the PCM for faulty connections Was a problem found Go to Step 13 Go to Step 12 12 Replace the PCM Refer to Powertrain Control Module PC...

Страница 1623: ...istory by using a scan tool D The DTC will be cleared from history when the vehicle has achieved 40 warmup cycles without a failure reported D The PCM will cancel the DTC default actions when the faul...

Страница 1624: ...ch on NOTE Before clearing DTC s use the scan tool to record Freeze Frame and Failure Records for reference as data will be lost when the Clear Info function is used 3 Record the DTC Freeze Frame and...

Страница 1625: ...matic Transmission 4L30 E section Is the replacement complete Go to Step 14 10 Check circuit RED WHT for an open or short to B Was a problem found Go to Step 14 Go to Step 11 11 Check circuit RED BLK...

Страница 1626: ...events occur seven consecutive times D The vehicle speed is less than 8 km h 5 mph D then the vehicle speed is 8 32 km h 5 20 mph for 4 seconds D then the vehicle speed is greater than 32 km h 20 mph...

Страница 1627: ...amp from cavity B13 2 of the brake switch connector to a known good ground Is the test lamp ON Go to Step 3 Go to Step 4 3 Install a J 36169 A Fused Jumper Wire from terminal B13 3 to terminal B13 2 o...

Страница 1628: ...to verify your repair perform the following procedure 1 Select DTC 2 Select Clear Info 3 With the engine off turn the ignition switch to the on position 4 Do not depress the brake pedal 5 Verify that...

Страница 1629: ...illuminate refer to DTC type definition type B Conditions For Clearing The MIL DTC D The PCM will turn off the MIL and CHECK TRANS Lamp after three consecutive ignition cycles without a failure repor...

Страница 1630: ...tween harness connector terminals J2 22 and J2 55 Is the reading 3 000 ohms Go to Step 5 Go to Step 6 5 1 Select AC volts 2 Rotate the rear wheels ensuring the driveshaft is turning Is the voltage gre...

Страница 1631: ...uit RED Is the repair complete Go to Step 17 16 Replace the PCM Refer to Powertrain Control Module PCM in automatic Transmission 4L30 E section Is the replacement complete Go to Step 17 17 1 After the...

Страница 1632: ...D Maximum line pressure D Inhibit TCC engagement D For lamp illumination refer to DTC type definition type B Conditions For Clearing The MIL DTC D The PCM will turn off the MIL and CHECK TRANS Lamp a...

Страница 1633: ...between harness connector terminals J2 22 and J2 55 Is the reading 3 000 ohms Go to Step 5 Go to Step 6 5 1 Select AC volts 2 Rotate the rear wheels ensuring the driveshaft is turning Is the voltage g...

Страница 1634: ...rcuit RED Is the repair complete Go to Step 17 16 Replace the PCM Refer to Powertrain Control Module PCM in Automatic Transmission 4L30 E section Is the replacement complete Go to Step 17 17 1 After t...

Страница 1635: ...cur seven consecutive times D The vehicle speed is greater than 32 km h 20 mph for 4 seconds D then the vehicle speed is between 8 32 km h 5 20 mph for 4 seconds D then the vehicle speed is less than...

Страница 1636: ...re Records then clear the DTC s 4 Select TCC Brake Switch on the scan tool 5 Disconnect the brake switch connector from the brake switch Did the TCC brake switch status change from Closed to Open Go t...

Страница 1637: ...is is a type C DTC Conditions For Setting The DTC D No Output Speed Sensor DTC s P0722 P0723 D Not in Park Neutral or Reverse D Engine speed is greater than 3 500 rpm D 3 seconds since upshift D No Tr...

Страница 1638: ...e you sent here from the On Board Diagnostic OBD System Check Go to Step 2 Go to OBD System Check Refer to Driveability and Emission in Engine section 2 Visually inspect the transmission cooling syste...

Страница 1639: ...ical Hydraulic Diagnosis Symptoms Index in Automatic Transmission 4L30 E section Was condition found and corrected Go to Step 7 7 1 After the repair is complete use the scan tool to select DTC then Cl...

Страница 1640: ...noid DTC P1860 D TP angle is greater than 20 D Engine speed is greater than 500 rpm and less than 3 000 rpm D Engine vacuum is between 0 and 70 kPa D Commanded gear is not 1st D Gear range is D4 D TCC...

Страница 1641: ...fo function is used 3 Record the DTC Freeze Frame and Failure Records 4 Using the scan tool verify the TP Sensor operation Are the TP Sensor values within 0 6 5 0 volts Go to Step 3 Go to Diagnostic A...

Страница 1642: ...tor OFF Durability Conditions For Clearing The DTC CHECK TRANS Lamp D The PCM will turn off the CHECK TRANS Lamp after three consecutive ignition cycles without a failure reported D The DTC can be cle...

Страница 1643: ...7 ohms Go to Step 7 Go to Step 4 4 1 Remove the transmission oil pan Refer to Solenoid Adapter Case Valve Body in Automatic Transmission 4L30 E section 2 Disconnect the internal wiring harness at the...

Страница 1644: ...conditions 1 2 occur two consecutive times Condition 1 D 2nd gear is commanded for 1 sec D 40 Engine Torque 400 N m D Throttle positon 10 D 800 TCC slip 4000 rpm D Speed ratio 0 6 D 2 75 Modeled Rati...

Страница 1645: ...nsmission range D1 D2 D3 D4 N R and P Does each selected transmission range match the TR Switch on the scan tool Go to Step 3 Go to Range Switch Logic Table 3 1 While the engine is operating raise the...

Страница 1646: ...cur two consecutive times Condition 1 D 1st gear is commanded for 1 sec D 40 Engine Torque 400 N m D Throttle positon 10 D 8000 TCC slip 8000 rpm D Transmission out speed 375 rpm D Speed ratio 0 3 D 1...

Страница 1647: ...smission range D1 D2 D3 D4 N R and P Does each selected transmission range match the TR Switch on the scan tool Go to Step 3 Go to Range Switch Logic Table 3 1 While the engine is operating raise the...

Страница 1648: ...oltage is between 10 and 16 volts D The PCM commands the solenoid on and the voltage remains high B or the PCM commands the solenoid off and the voltage remains low zero volts D All conditions met for...

Страница 1649: ...learing DTC s use the scan tool to record Freeze Frame and Failure Records for reference as data will be lost when the Clear Info function is used 3 Record the DTC Freeze Frame and Failure Records Wer...

Страница 1650: ...d Go to Step 19 14 The wiring harness between PCM connector J1 or J2 and transmission 16 way connector H 56 is open or poor connection Was a problem found and corrected Go to Step 19 15 The wiring har...

Страница 1651: ...two consecutive times Condition 1 D 1st gear is commanded for 1 sec D 40 Engine Torque 400 N m D Throttle position 10 D 2300 TCC slip 200 rpm D Transmission out speed 400 rpm D Speed ratio 0 3 D 0 60...

Страница 1652: ...each selected transmission range match the TR Switch on the scan tool Go to Step 3 Go to Range Switch Logic Table 3 1 While the engine is operating raise the drive wheels 2 With the transmission in D4...

Страница 1653: ...ccur two consecutive times Condition 1 D 3rd gear is commanded for 1 sec D 40 Engine Torque 400 N m D Throttle positon 10 D 8000 TCC slip 8000 rpm D Transmission out speed 375 rpm D Speed ratio 0 6 D...

Страница 1654: ...ach selected transmission range match the TR Switch on the scan tool Go to Step 3 Go to Range Switch Logic Table 3 1 While the engine is operating raise the drive wheels 2 With the transmission in D4...

Страница 1655: ...and 16 volts D The PCM commands the solenoid on and the voltage remains high B or the PCM commands the solenoid off and the voltage remains low zero volts D All conditions met for 0 84 1 0 seconds Ac...

Страница 1656: ...will be lost when the Clear Info function is used 3 Record the DTC Freeze Frame and Failure Records Were DTCs P0753 P0758 P1860 set Go to Step 4 Go to Step 3 3 1 The engine on 2 Apply brake pedal and...

Страница 1657: ...sion 16 way connector H 56 Was a problem found and corrected Go to Step 26 Go to Step 14 14 1 Connect the J1 BLUE and J2 RED PCM connectors to the PCM 2 Turn the ignition on the engine on 3 Repeat Ste...

Страница 1658: ...rminal H56 12 and transmission main case connector terminal M7 6 A or between H56 11 and M7 2 D is open Was a problem found and corrected Go to Step 26 24 The internal wiring harness from the shift so...

Страница 1659: ...ying a voltage to one side the High side and a ground to the other side Low side D The High Side Driver HSD is a circuit of the PCM that acts as a switch between the solenoids and the supply voltage T...

Страница 1660: ...rn the ignition switch on NOTE Before clearing DTC s use the scan tool to record Freeze Frame and Failure Records for reference as data will be lost when the Clear Info function is used 3 Record the D...

Страница 1661: ...terminal H56 9 and ground Is there a continuity Go to Step 16 Go to Step 22 15 1 Disconnect the transmission main case connector M 7 2 Using the J39200 DVOM measure the resistance between terminals M...

Страница 1662: ...orrected Go to Step 27 25 The wiring harness between the transmission 16 way connector terminal H56 9 and the transmission main case connector terminal M7 7 B is open Was a problem found and corrected...

Страница 1663: ...n D The PCM commands the solenoid on and the voltage remains low zero volts D The PCM commands the solenoid off and the voltage remains high B D All conditions met for 0 875 1 25 seconds Action Taken...

Страница 1664: ...10 0 5 ohms at 20 C 68 F Go to Step 7 Go to Step 8 6 The wiring harness between PCM connector terminal J2 51 and transmission adapter case connector terminal M6 1 A is shorted to voltage Was a proble...

Страница 1665: ...problem found and corrected Go to Step 21 17 The wiring harness between transmission 4 way connector terminal H54 2 and adapter case terminal M6 1 A is open Was a problem found and corrected Go to St...

Страница 1666: ...is between 250 rpm and 800 rpm for 3 times 7 seconds D Vehicle speed is between 25 km h 15 mph and 225 km h 158 mph D Speed ratio is between 0 6 and 0 95 D ECCC is ON D Low 0 8 TCC Capacity hi 0 99 fo...

Страница 1667: ...e you sent here from the Powertrain On Board Diagnostic OBD System Check Go to Step 2 Go to OBD System Check Refer to Driveability and Emissions in Engine section 2 1 Install the scan tool 2 With the...

Страница 1668: ...7A1 84 TRANSMISSION CONTROL SYSTEM 4L30 E Connector List No Connector face No Connector face B 13 H 41 E 53 J2 H 53 E 54 J1 H 54 H 8 H 55 H 10 H 56 H 11 H 57 H 24 I 9 H 25 M 6 H 32 M 7...

Страница 1669: ...TRANSMISSION CONTROL SYSTEM 4L30 E 7A1 85 No Connector face No Connector face M 15 M 25...

Страница 1670: ...INFORMATION FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT PERSONAL INJURY OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS CAUTION Always use the correct fastener in the proper locati...

Страница 1671: ...7B 2 MANUAL TRANSMISSION General Description A07RW023...

Страница 1672: ...n Replace Shift arm and synchronizer sleeve groove worn Replace worn parts Thrust washer collar and or gear thrust faces worn Mainshaft and counter shaft thrust play Replace worn parts Synchronizer pa...

Страница 1673: ...e front console assembly 5 Remove the grommet assembly 6 Remove the transmission control lever and transfer control lever 235RX001 7 Remove transfer protector 8 Remove the rear propeller shaft NOTE Ap...

Страница 1674: ...speed sensor and 2WD 4WD actuator harness connectors 225RW007 12 Disconnect the 4WD indicator harness connector 220RW006 13 Remove two transmission harness clamps from the transmission case and bracke...

Страница 1675: ...7B 6 MANUAL TRANSMISSION 141RW024 15 Remove the heat protector 225RW006 16 Remove the slave cylinder 206RW002...

Страница 1676: ...lts 24 Remove the rear mount from the transmission 25 Remove three flywheel under cover 26 Support the transmission with a transmission jack and then remove jack from the transfer case side 220RS001 2...

Страница 1677: ...e transmission disassembly required Refer to Transfer Case in Drive Line Axle section Installation 1 Apply a thin coat of molybdenum disulfide grease to the top gear shaft spline 2 Slowly operate the...

Страница 1678: ...release bearing NOTE A clicking sound is heard when the release bearing and the tip of the diaphragm spring engage each other Check to see if they are securely engaged by pushing the tip of the shift...

Страница 1679: ...d crossmember to the frame and tighten the fixing bolts specified torque Torque 50 N m 37 lb ft 12 Tighten the engine rear mount nuts specified torque Torque 50 N m 37 lb ft 13 Remove the transmission...

Страница 1680: ...UAL TRANSMISSION 7B 11 141RW024 19 Install bracket and two transmission harness clamps to the transmission case 220RS028 20 Connect the speedometer sensor and 2WD 4WD actuator harness connector 225RW0...

Страница 1681: ...Install the rear propeller shaft and tighten the fixing bolts and nuts specified torque Torque 63 N m 46 lb ft 24 Install transfer protector and tighten the fixing bolts specified torque Torque 37 N m...

Страница 1682: ...4 2nd Gear 15 Synchronizer Assembly 16 Clutch Hub No 1 Assembly 17 Snap Ring 18 Synchronizer Assembly 19 1st Gear 20 1st Gear Bearing Spacer 21 1st Gear Needle Roller Bearing 22 1st Gear Thrust Washer...

Страница 1683: ...Gear Spline Piece 44 Snap Ring 226RW181 Legend 1 3rd 4th Shift Arm 2 1st 2nd Shift Arm 3 3rd 4th Shift Rod 4 Ball 5 Spring 6 1st 2nd Shift Rod 7 Snap Ring 8 Interlock Pin 9 Reverse Shift Arm Bracket 1...

Страница 1684: ...3 Front Cover 4 Snap Ring 5 Snap Ring 6 1st and 2nd Switch 7 Drain Plug 8 Backup Light Switch 9 Plug 10 Transmission Case 11 Filler Plug 12 Oil Receiver Pipe 13 Reverse Restrict Pin 14 Gear Control Ro...

Страница 1685: ...move the clutch release bearing and shift fork 1 Remove the clutch release bearing 3 from the front cover 2 Remove the split pin 4 Remove the shaft from the under Remove the shift fork 5 220RW086 3 Re...

Страница 1686: ...lutch housing 220RW008 5 Remove gear control box and gasket 1 Remove the 6 bolts gear control box and gasket 230RW001 6 Remove transfer adapter 1 Using a hexagon wrench remove the plug 1 220RW010 2 Us...

Страница 1687: ...gear control rod 220RW098 4 Remove the 10 bolts and clamp 220RW016 5 Using a plastic hammer tap the transfer adapter NOTE D Be careful not to lose the pin D Cover the mainshaft splines with adhesive t...

Страница 1688: ...ammer drive out the slotted spring pin Remove the reverse restrict pin 220RW012 3 Remove the oil receiver pipe 220RW011 4 Remove the oil seal 5 Using socket hexagon wrench remove the plug 220RW014 8 R...

Страница 1689: ...he front cover oil seal 1 Mount the front cover through the aluminum plate in a vise 2 Using screwdriver remove oil seal 1 220RW019 10 Remove the transmission case 1 Using a snap ring expander remove...

Страница 1690: ...m plate in a vise 226RW005 12 Remove the slotted spring pin 1 Using a pin punch and hammer drive out the pin from the arm 226RW025 13 Remove the shift arm set bolt 1 Remove the 2 bolts from the shift...

Страница 1691: ...ove the hub sleeve No 3 block ring set counter 5th gear bearing and 5th shift arm 220RW101 4 Remove the synchronizer pull ring synchronizer cone ring and synchronizer outer ring from hub sleeve No 3 2...

Страница 1692: ...om counter gear shaft 226RW018 16 Remove the bearing plate 1 Remove the 4 bolts and bearing retainer 226RW016 17 Remove the reverse idle gear 1 Pull out the shaft foward the rear and remove the revers...

Страница 1693: ...t to drop the counter gear when removing the bearing 226RW036 3 Remove the counter gear from intermediate plate 226RW030 19 Disassemble the counter gear shaft assembly 1 Using snap ring pliers remove...

Страница 1694: ...e top gear shaft from mainshaft NOTE Don t fall needle roller bearing 226RW029 2 Remove the 4th block ring and roller bearing 226RW031 21 Disassemble the top gear shaft assembly 1 Check for wear or da...

Страница 1695: ...ring 226RW069 22 Remove the mainshaft 1 Remove mainshaft bearing snap ring 226RW035 2 Using a plastic hammer tap the 5th reverse shift rod at the reverse shift side 226RW034 3 Remove the intermediate...

Страница 1696: ...gear thrust clearance Gear Standard Clearanse 1st 0 15 0 45 mm 0 0059 0 0177 in 2nd 0 10 0 25 mm 0 0039 0 0098 in 3rd 0 10 0 25 mm 0 0039 0 0098 in 226RW070 2 Inspect each gear radial clearance 1 Usi...

Страница 1697: ...ng parts from mainshaft 1 Synchronizer assembly 1 2 1st gear thrust washer pin 3 3 1st gear needle roller bearing 4 4 1st gear bearing spacer 2 226RW146 6 Using 2 screwdrivers and hammer tap out snap...

Страница 1698: ...nsert spring with a screwdriver 226RW075 10 Remove the snap ring NOTE Don t damage the bearing surface 226RW076 11 Using a press remove following parts 1 Clutch hub No 2 assembly 1 2 3rd block ring 2...

Страница 1699: ...he aluminum plate in a vise 2 Using a plastic hammer tap the 5th shift rod on the neutral 226RW052 3 Using a torx socket wrench T40 remove the 4 plugs 226RW050 4 Using a magnetic finger remove 3 sprin...

Страница 1700: ...t the 3rd 4th shift rod at the rear 226RW047 7 Using a magnetic finger remove the interlock pin and straight pin 226RW043 8 Pull out the 1st 2nd shift rod at the rear 226RW045 9 Using a magnetic finge...

Страница 1701: ...the 5th reverse shift rod at the front 226RW040 12 Using a magnetic finger remove the interlock pin from the intermediate plate Remove the ball from the reverse shift arm No 1 226RW039 13 Pull out at...

Страница 1702: ...remove at the rear 226RW055 15 Using a magnetic finger remove the ball and spring from reverse shift arm No 1 226RW056 16 Remove the reverse shift arm No 2 E ring Remove the reverse shift arm No 2 fr...

Страница 1703: ...th gear radial clearance Standard 0 015 0 068 mm 0 00059 0 00268 in 226RW183 4 Using a inside dial indicator measure the gear inside diameter Standard 38 015 38 040 mm 1 49665 1 49763 in 226RW085 2 5t...

Страница 1704: ...ise 2 Using a dial indicator measure the reverse idle gear radial clearance Standard 0 040 0 082 mm 0 0016 0 0032 in 226RW083 3 If the clearance exceeds the maximum measure the gear inside diameter an...

Страница 1705: ...2 Select a snap ring that will allow minimum axial play Mark Thickness A 2 10 2 15 mm 0 083 0 085 in B 2 15 2 20 mm 0 085 0 087 in C 2 20 2 25 mm 0 087 0 089 in D 2 25 2 30 mm 0 089 0 091 in E 2 30 2...

Страница 1706: ...k replace the block ring 226RW060 7 Install the needle roller bearing 2 Reassemble the mainshaft assembly NOTE Apply all parts with gear oil before installing them 3 Inspect block ring 1 Using a thick...

Страница 1707: ...of the shift arm thickness Reference 10 0mm 0 39 in 2 Using a vernier caliper measure center groove of the hub sleeve No 2 Calculate the clearance between the hub sleeve No 2 and shift arm Reference C...

Страница 1708: ...984 38 000 mm 1 4954 1 4961 in B 46 984 47 000 mm 1 8498 1 8504 in C 38 979 38 995 mm 1 5346 1 5352 in 226RW078 2 Using a micrometer measure the mainshaft flange thickness Standard 5 0 mm 0 197 in 226...

Страница 1709: ...sert springs so that their end gaps are not in line 226RW099 3 Using installer J 42797 and a press install the clutch hub No 2 and hub sleeve No 2 to the mainshaft NOTE D Align the block ring slots wi...

Страница 1710: ...a thickness gauge inspect the 3rd gear thrust clearance Standard 0 10 0 25mm 0 004 0 010 in 226RW103 10 Install the 2nd gear 1 Install the synchronizer ring set NO 1 to the 2nd gear NOTE Align the nai...

Страница 1711: ...tion as shown 226RW109 3 Using installer J 42798 and a press install the hub No 1 by retaining the reverse gear NOTE D Align the projection of inner ring with hub No 1 slots D Check that the gear rota...

Страница 1712: ...0 10 0 25mm 0 004 0 010 in 226RW113 12 Install the 1st gear 1 Install the following parts 1 1st gear bearing spacer 4 2 1st gear needle roller bearing 3 3 Synchronizer assembly 2 4 1st gear 1 NOTE D A...

Страница 1713: ...42799 and a press install the 5th gear 2 Select a snap ring that will allow minimum axial play Mark Thickness C 2 75 2 80 mm 0 108 0 110 in D 2 80 2 85 mm 0 110 0 112 in E 2 85 2 90 mm 0 112 0 114 in...

Страница 1714: ...71 16 Install the counter gear shaft 1 Check the new counter front bearing inner race and the side race as shown 2 Using installer J 42800 and a press install the counter gear shaft front bearing 226R...

Страница 1715: ...5 mm 0 46 0 02 in 2 Apply grease to the seal lip 220RW023 18 Install the transfer adapter 1 Using installer J 42802 and a hammer drive in a new oil seal Drive in depth from transfer adapter 10 95 0 5...

Страница 1716: ...threads THREE BOND 1344 or equivalent 8 Using a torx socket wrench T40 install and torque the plug Torque 18 5 N m 13 5 lb ft 220RW013 9 Using hexagon wrench install and torque the plug Torque 37 N m...

Страница 1717: ...se shift arm No 2 to the reverse shift arm No 1 Using screwdriver and a hammer install the new E ring 226RW138 4 Install reverse shift arm No 2 to the reverse shift arm bracket 226RW012 20 Install the...

Страница 1718: ...se 5th shift rod 1 Install the reverse shift arm No 1 lock ball to the reverse shift arm No 1 2 Install the interlock pin to the intermediate plate 226RW039 3 Put in the reverse 5th shift rod from the...

Страница 1719: ...e interlock pin to the intermediate plate 226RW042 2 Put in the 1st 2nd shift rod from the rear 226RW044 23 Install 3rd 4th shift rod 1 Install the straight pin and interlock pin to the intermediate p...

Страница 1720: ...s to the intermediate plate 226RW049 3 Clean up the plug hole 4 Apply sealant to the plug threads sealant three bond 1344 or equivalent 5 Using a torx socket wrench T40 install and torque the 4 plugs...

Страница 1721: ...10 3 Using a plastic hammer tap the intermediate plate and install the mainshaft Through the shift arm No 1 and No 2 to the shift rod 226RW009 4 Using a snap ring expander install the snap ring 226RW0...

Страница 1722: ...eck that the gear rotates smoothly 226RW006 27 Install the counter gear shaft 1 Temporarily install the counter gear shaft to the intermediate plate 226RW028 2 Using installer J 42796 and a hammer dri...

Страница 1723: ...erse idle gear shaft Torque 12 5 N m 109 lb in 226RW016 30 Install the 5th gear thrust washer 1 Install the 5th gear thrust washer pin to the counter gear shaft 2 Install the 5th gear thrust washer to...

Страница 1724: ...121 3 Turn to 30 degree the reverse synchronizer pull ring 226RW080 4 Install the hub sleeve No 3 and reverse block ring set to the counter 5th gear NOTE Check the hub sleeve No 3 direction as shown R...

Страница 1725: ...rojection of the cone ring to the holes of the 5th gear spline piece D Check that the gear rotates smoothly 226RW013 8 Using thickness gauge measure the counter 5th gear thrust clearance Standard 0 10...

Страница 1726: ...Torque 19 5 N m 14 lb ft 226RW023 33 Install the shift arm slotted pin 1 Using a pin punch and a hammer drive in the slotted pin to the shift arm 226RW025 34 Install the transmission case 1 Clean up...

Страница 1727: ...haft bearing snap ring 2 226RW004 6 Turn over the transmission 35 Install the front cover 1 Clean up the fitting surface 2 Apply recommended liquid gasket THREE BOND 1281 or equivalent as shown NOTE D...

Страница 1728: ...026 3 Using a plastic hammer tap the transfer adapter and attach it to the intermediate plate 220RW034 4 Using 10 bolts install the transfer adapter Torque 37 N m 27 lb ft NOTE D Tighten the all bolts...

Страница 1729: ...D 1344 or equivalent to the plug 1 thread 4 Using hexagon wrench install and torque the plug 1 Torque 18 N m 13 lb ft 220RW010 5 Clean up the bolts and bolt hole 6 Using 6 bolts install the gear contr...

Страница 1730: ...ease grease 1 Fitting surface of the cylinder push rod 2 Fitting surface of the release bearing hub 3 The hole of the fork split pin 4 2 Apply the clutch release grease 1 The spline surface of the top...

Страница 1731: ...synchronized forward and reverse gears Control method Direct control with the gear shift lever on the floor Gear ratio 1st 3 954 2nd 2 330 3rd 1 436 4th 1 000 5th 0 788 Rev 3 918 Oil capacity lit US q...

Страница 1732: ...MANUAL TRANSMISSION 7B 63 E07RW030...

Страница 1733: ...ounter gear shaft center bearing installer J 42797 Clutch hub No 2 installer J 42798 Clutch hub No 1 installer ILLUSTRATION TOOL NO TOOL NAME J 42799 Installer J 42800 Counter gear shaft front bearing...

Страница 1734: ...MANUAL TRANSMISSION 7B 65 ILLUSTRATION TOOL NO TOOL NAME J 22912 01 Bearing separator...

Страница 1735: ...OR THE SRS WIRING WHEN YOU ARE PERFOMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING REFER TO THE SRS SERVICE INFORMATION FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLO...

Страница 1736: ...H General Description Clutch A07RW046 For 6VE1 3 5L engine model the pull type clutch is employed The pull type clutch is disengaged by pulling the release lever release bearing to disengage the press...

Страница 1737: ...CLUTCH 7C 3 Master Cylinder A07RW007 Slave Cylinder A07RS005...

Страница 1738: ...7C 4 CLUTCH Pressure Plate Assembly A07RS006...

Страница 1739: ...CLUTCH 7C 5 Driven Plate Assembly A07RS007...

Страница 1740: ...ster cylinder and slave cylinder seals worn Replace seals Chattering Engine mounts loose or damaged Tighten or replace Driven plate facing warped Replace driven plate Surface of facing hardened Replac...

Страница 1741: ...e Assembly 4 Transmission Assembly 5 Front Cover 6 Shift Fork 7 Release Bearing Removal 1 Remove transmission assembly refer to MANUAL TRANSMISSION of Section 7B for Removal AND INSTALLATION procedure...

Страница 1742: ...flywheel assembly and crankshaft bearing do not remove except for replacement 11 Use the remover J 5822 and sliding hammer J 23907 to remove the crankshaft bearing 015RW050 Inspection and Repair Make...

Страница 1743: ...stance B becomes 12 mm 0 472 in 4 Note the pressure gauge reading 5 If the measured value is less than the specified limit the pressure plate assembly must be replaced Clutch Set Force Standard 7208 N...

Страница 1744: ...ub 2 The clutch pilot aligner J 24547 must be held perfectly horizontal 3 Set a dial indicator to the driven plate outside circumference 4 Slowly turn the driven plate 5 Read the dial indicator as you...

Страница 1745: ...0 2 mm 0 008 in Release Bearing 201RS011 1 Visually check the release bearing for excessive play noise and breakage 2 If any of these conditions are discovered the release bearing must be replaced 3 W...

Страница 1746: ...and driver handle J 8092 to install the crankshaft bearing then clean and lubricate with grease 015RS046 2 Install new flywheel fixing bolts in the order illustrated and tighten them to the specified...

Страница 1747: ...areas shown in illustration 201RW012 9 Install the release bearing in the proper direction NOTE Ensure release bearing is properly positioned during installation as shown in illustration 201RW020 10 I...

Страница 1748: ...mbly and tighten the bolts holding the pressure plate assembly in the order shown in illustration Torque 18 N m 13 lb ft 201RS017 12 Remove the aligner NOTE Do not strike the aligner with a hammer to...

Страница 1749: ...ly and Heat Protector Removal 1 Remove pin and jaw joint pin 2 Remove pedal assembly and switch 3 Remove oil line pipe 4 Remove slave cylinder assembly and heat protector 5 Remove master cylinder asse...

Страница 1750: ...switch out until there is a gap between the switch plunger and clutch pedal 203RW003 Legend 1 Push Rod 2 Clutch Switch 2 Loosen clutch master cylinder push rod lock nut Turn push rod by hand to set cl...

Страница 1751: ...203RW004 6 Clutch pedal engagement height inspection 1 Operate the parking brake lever and block the wheels 2 Start the engine fully step on the clutch pedal and move the shift lever to 1st position 3...

Страница 1752: ...ry 2 Bleeding the slave cylinder 1 Remove the rubber cap from the bleeder screw and wipe clean the bleeder screw Connect a vinyl tube to the bleeder screw and insert the other end of the vinyl tube in...

Страница 1753: ...spection and Repair Inspect the removed parts If there are abnormalities such as wear oil leak or other damage replace the master cylinder assembly NOTE The master cylinder assembly cannot be disassem...

Страница 1754: ...2 Remove push rod 3 Remove piston and piston cup 4 Remove spring 5 Remove cylinder body Inspection and Repair Make the necessary adjustments repairs and part replacements if excessive wear or damage...

Страница 1755: ...on 4 If the measured value exceeds the specified limit the slave cylinder assembly must be replaced Standard 0 07 mm 0 0028 in Limit 0 15 mm 0 0059 in 206RS005 Reassembly To reassemble follow the disa...

Страница 1756: ...pring finger height 49 9 51 9 mm 1 965 2 043 in Driven plate Outside diameter x inside diameter 275 180 mm 10 83 6 69 in Thickness Clutch disengaged 8 8 mm 0 346 in Thickness Clutch engaged 8 3 mm 0 3...

Страница 1757: ...CLUTCH 7C 23 Torque Specifications Cont d E07RX001...

Страница 1758: ...CLUTCH Special Tools ILLUSTRATION TOOL NO TOOL NAME J 24547 Driven plate aligner J 5822 and J 23907 Pilot bearing remover and Sliding hammer J 26516 A Crankshaft pilot bearing installer J 8092 Driver...

Страница 1759: ...8A 9 Removal 8A 9 Installation 8A 9 Backup Light Bulb 8A 10 Removal 8A 10 Installation 8A 10 Dome Light Bulb 8A 10 Removal 8A 10 Installation 8A 10 Luggage Room Light Bulb 8A 11 Removal 8A 11 Install...

Страница 1760: ...fastener in the proper location When you replace a fastener use ONLY the exact part number for that application ISUZU will call out those fasteners that require a replacement after removal ISUZU will...

Страница 1761: ...o remove the headlight assembly with bracket 6 Remove the headlight bulb 7 Remove two screws two nuts and the spring for the headlight aim adjustment to remove the bracket 8 Remove four screws to remo...

Страница 1762: ...1 Disconnect the battery ground cable 2 Open the rear cover 1 of the case 3 Remove the dust cover 4 Disconnect the bulb connector 5 Remove the clip 3 6 Remove the fog light bulb 2 801RS004 Installati...

Страница 1763: ...Light Adjustment Turn the adjusting screw with a screwdriver to adjust the aim of the fog light vertically 801RW007 Front Side Marker Light Bulb Removal 1 Disconnect the battery ground cable 2 Remove...

Страница 1764: ...connect the battery ground cable 2 Remove three screws and release locks at two locations to remove the rear combination light assembly 2 3 Remove the socket 3 by turning it counterclockwise 4 Turn th...

Страница 1765: ...socket 803RS006 Installation To install follow the removal steps in the reverse order Stoplight Bulb Removal and Installation Refer to the Taillight Bulb in this section High Mount Stoplight Removal...

Страница 1766: ...nect the battery ground cable 2 Remove the screw at the upper portion of the light bracket and remove the bracket from the fender 3 Remove the front combination light 1 4 Remove the turn signal light...

Страница 1767: ...at the same time 803RS002 Installation To install follow the removal steps in the reverse order Cornering Light Bulb Removal 1 Disconnect the battery ground cable 2 Remove the screws at the upper port...

Страница 1768: ...1 by turning it counterclockwise 5 Remove the bulb 2 by turning it counterclockwise while pushing it at the same time 803RS001 Installation To install follow the removal steps in the reverse order Do...

Страница 1769: ...four locations 3 Remove the bulb 1 803RS007 Installation To install follow the removal steps in the reverse order Courtesy Light Bulb Removal 1 Disconnect the battery ground cable 2 Remove two screws...

Страница 1770: ...he socket counterclockwise to remove it 6 Pull out the bulb from the socket 805RS008 Installation To install follow the removal steps in the reverse order Cigarette Lighter Illumination Bulb Removal 1...

Страница 1771: ...dio box 4 5 Remove two screws to remove the ashtray guide 2 6 Turn the socket counterclockwise to remove it then pull out the bulb 3 742RS001 Installation To install follow the removal steps in the re...

Страница 1772: ...able 2 Remove the front console assembly 1 Refer to Instrument Panel Assembly in Body Structure section 3 Remove the lower cluster assembly 2 Refer to the Instrument Panel Assembly in Body Structure s...

Страница 1773: ...ove four fixing screws and disconnect the driver inflator module connector to remove the driver inflator module 3 CAUTION When carrying a live inflator module make sure the bag opening is pointed away...

Страница 1774: ...lock type of inflator module connector insert the connector completely and lock at outside Imperfect locking may cause malfunction of SRS system circuit 4 When installing the steering cowl 11 be sure...

Страница 1775: ...toplight Switch W O Cruise Control Removal 1 Disconnect the battery ground cable 2 Disconnect the connector 3 loosen the lock nut 1 and then remove the stoplight switch 2 by turning it 310RS007 Instal...

Страница 1776: ...ch counterclockwise until the space between the tip of the threaded portion and the pedal arm is 0 5 to 1 0 mm 0 02 0 04 in 310RS003 Turn Signal Switch Cornering Light Switch Combination Switch Remova...

Страница 1777: ...embly to remove the hazard warning switch 5 825RW024 Installation To install follow the removal steps in the reverse order noting the following point 1 Push in the switch with your fingers until it lo...

Страница 1778: ...the Instrument Panel Assembly in Body Structure section 3 Remove the lower cluster assembly 2 Refer to the Instrument Panel Assembly in Body Structure section 4 Remove the instrument panel driver lowe...

Страница 1779: ...and disconnect the switch connectors to remove the front console assembly 4 3 Push the lock from the back side of the front console assembly to remove the seat heater switch 5 825RW025 Installation To...

Страница 1780: ...ower cover assembly 3 Refer to the Instrument Panel Assembly in Body Structure section 821RW024 5 Remove the instrument panel cluster assembly 4 Refer to the Instrument Panel Assembly in Body Structur...

Страница 1781: ...14 Backup Light 15 Taillight Stoplight 16 Rear Combination Light Light Name Bulb No Rated Power Number of Bulbs Lens Color Remarks Headlight 9004 65W 45W 2 White Halogen Front Combination Turn Signal...

Страница 1782: ...river 74 1 4W 1 Green Meter Turn Signal 74 1 4W 2 Green Meter Upshift 74 1 4W 1 Amben Meter High Beam 74 1 4W 1 Blue Meter Indicator ABS 74 1 4W 1 Amben Meter Indicator Warning light Seat Belt 80 2W 1...

Страница 1783: ...val and Installation 8B 11 Main Data and Specifications 8B 11 Service Precaution WARNING THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM SRS REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORD...

Страница 1784: ...or to activate the wiper The washer motor squirts glass cleaning fluid while the washer switch is being pushed The intermittent relay is used to control motion of the wiper Windshield Wiper And Washer...

Страница 1785: ...e 1 3 Remove the screws and then remove the front combination light 2 4 Remove 2 screws the filler neck and the hose 5 Disconnect the windshield washer motor connector and remove the washer tank 4 6 P...

Страница 1786: ...bly 4 Windshield Wiper Motor Removal 1 Disconnect the battery ground cable 2 Remove the windshield wiper arm blade 3 Remove the windshield wiper motor 4 Remove the pivot assembly mounting nuts fixing...

Страница 1787: ...teps in the reverse order noting the following points 880RS004 1 Wiper arm blade D Before installing the wiper arm blade to the shaft confirm that the motor stops at the auto stop position D Set the w...

Страница 1788: ...80RS011 2 Pull the end of rubber and remove the projection 3 from the click of the blade stay 2 880RS010 3 Pull the rubber out in the same direction Installation To install follow the removal steps in...

Страница 1789: ...ble 2 Remove the front console assembly 1 Refer to the Instrument Panel Assembly in Body Structure section 3 Remove the lower cluster assembly 2 Refer to the Instrument Panel Assembly in Body Structur...

Страница 1790: ...tall follow the removal steps in the reverse order noting the following points 1 Before installing the wiper arm blade to the motor shaft confirm that the motor stops at the auto stop position 2 Insta...

Страница 1791: ...e connectors and then remove the alarm relay control unit 1 826RW020 Installation To install follow the removal steps in the reverse order Rear Washer Motor Removal 1 Disconnect the battery ground cab...

Страница 1792: ...per Washer System section Rear Washer Nozzle Removal 1 Disconnect the hose 3 2 Remove the lock nut 2 and then remove the washer nozzle 1 885RS005 Installation To install follow the removal steps in th...

Страница 1793: ...er Blade Rubber Removal and Installation Refer to the Windshield Wiper Blade Rubber in this section Main Data and Specifications Torque Specifications Application N m Lb Ft Lb In Windshield Wiper Moto...

Страница 1794: ...CE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING REFER TO THE SRS SERVICE INFORMATION FAILURE TO FOLLOW WARNINGS COULD...

Страница 1795: ...te lighter 3 and socket 4 the bezel 5 and then remove the cigarette lighter assembly 2 826RS007 Installation To install follow the removal steps in the reverse order noting the following point 1 When...

Страница 1796: ...ntil it locks securely Rod Type Antenna Removal 1 Disconnect the battery ground cable 2 Turn the antenna rod 1 counterclockwise to remove it 3 Remove three screws and nine clips to remove the fender i...

Страница 1797: ...ty Glass Antenna Glass Antenna System Parts Location 890RW014 Legend 1 Glass Antenna LH 2 Glass Antenna Amplifier 3 Glass Antenna RH 4 Glass Antenna Amplifier 5 Connection with the audio side feeder c...

Страница 1798: ...ove the luggage side trim cover Refer to the Interior Trim Panels removal steps in Exterior Interior Trim section 3 Disconnect the connector 1 4 feeder cable 3 and remove two screws to remove the glas...

Страница 1799: ...Body Structure section 4 Remove the instrument panel driver lower cover assembly 3 Refer to the Instrument Panel Assembly in Body Structure section 821RW024 5 Remove the instrument panel cluster assem...

Страница 1800: ...the connector 3 to remove the speaker 2 890RW013 Installation To install follow the removal steps in the reverse order Tweeter Assembly Removal 1 Disconnect the battery ground cable 2 Pull the tweeter...

Страница 1801: ...onnect the battery ground cable 2 Pull the grille 1 to release the locks and then remove it 3 Remove four screws and disconnect the connector 3 to remove the speaker 2 890RW015 Installation To install...

Страница 1802: ...8D 1 WIRING SYSTEM TROOPER BODY AND ACCESSORIES WIRING SYSTEM CONTENTS Fuse Relay and Diode 8D 2 Relay and Fuse Box Fuse Box Location 8D 2 Relay Fuse Box 8D 3 Fuse Box 8D 4 Circuit Diagram 8D 5...

Страница 1803: ...8D 2 WIRING SYSTEM Fuse Relay and Diode Relay and Fuse Box Fuse Box Location 810RY00003 Legend 1 Relay and Fuse Box 2 Fuse Box...

Страница 1804: ...Upshift Relay 1 18 Starter Relay 19 Not Used 20 Not Used 21 Not Used 22 Not Used 23 Cornering Relay 24 Fog Light Relay 25 Fusible Link Main 26 Fusible Link Key SW 27 Fusible Link ECM 28 Fusible Link...

Страница 1805: ...1 Not Used 12 Diode Not Used 13 Fuse C 1 10A 14 Fuse C 2 15A 15 Fuse C 3 15A 16 Fuse C 4 15A 17 Fuse C 5 15A 18 Fuse C 6 10A 19 Fuse C 7 Not Used 20 Fuse C 8 15A 21 Fuse C 9 15A 22 Fuse C 10 10A 23 F...

Страница 1806: ...8D 5 WIRING SYSTEM Circuit Diagram...

Страница 1807: ...8D 6 WIRING SYSTEM Fuse Block Circuit...

Страница 1808: ...8D 7 WIRING SYSTEM Starter and Generator...

Страница 1809: ...8D 8 WIRING SYSTEM PCM 1...

Страница 1810: ...8D 9 WIRING SYSTEM PCM 2...

Страница 1811: ...8D 10 WIRING SYSTEM Headlight and Fog Light...

Страница 1812: ...8D 11 WIRING SYSTEM Illumination Light...

Страница 1813: ...8D 12 WIRING SYSTEM Turn Signal Light and Hazard Warning Light...

Страница 1814: ...8D 13 WIRING SYSTEM Stoplight and Rear Defogger...

Страница 1815: ...8D 14 WIRING SYSTEM Dome Light Courtesy Light Stop Light and Luggage Room Light...

Страница 1816: ...8D 15 WIRING SYSTEM Door Lock W Keyless Entry...

Страница 1817: ...8D 16 WIRING SYSTEM Door Lock W O Keyless Entry...

Страница 1818: ...8D 17 WIRING SYSTEM Power Window...

Страница 1819: ...8D 18 WIRING SYSTEM Cruise Control...

Страница 1820: ...8D 19 WIRING SYSTEM ABS 1...

Страница 1821: ...8D 20 WIRING SYSTEM ABS 2...

Страница 1822: ...8D 21 WIRING SYSTEM A T Shift Lock...

Страница 1823: ...8D 22 WIRING SYSTEM Anti theft W Keyless Entry...

Страница 1824: ...8D 23 WIRING SYSTEM Windshield Wiper and Washer...

Страница 1825: ...8D 24 WIRING SYSTEM Audio...

Страница 1826: ...8D 25 WIRING SYSTEM Door Mirror...

Страница 1827: ...8D 26 WIRING SYSTEM Meter W T O D...

Страница 1828: ...8D 27 WIRING SYSTEM Meter W O T O D...

Страница 1829: ...8D 28 WIRING SYSTEM A T Shift Indicator...

Страница 1830: ...8D 29 WIRING SYSTEM Air Conditioning Manual...

Страница 1831: ...8D 30 WIRING SYSTEM Air Conditioning Auto 1...

Страница 1832: ...8D 31 WIRING SYSTEM Air Conditioning Auto 2...

Страница 1833: ...8D 32 WIRING SYSTEM Sun Roof...

Страница 1834: ...8D 33 WIRING SYSTEM Seat Heater...

Страница 1835: ...8D 34 WIRING SYSTEM SRS Air Bag...

Страница 1836: ...8D 35 WIRING SYSTEM Shift on the Fly...

Страница 1837: ...8D 36 WIRING SYSTEM Torque on Demand T O D...

Страница 1838: ...8D 37 WIRING SYSTEM Alarm and Relay Control Unit...

Страница 1839: ...RS SERVICE INFORMATION FAILURE TO FOLLOW WARNINGS COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT PERSONAL INJURY OR OTHERWISE UNNEEDED SRS SYSTEM REPAIRS CAUTION Always use the correct fastener in the pr...

Страница 1840: ...icator light or the meter assembly not containing TOD has the voltmeter and oil pressure gauge instead of the TOD indicator Layout for Meters Gauges Warning Lights Indicator Lights and Illumination Li...

Страница 1841: ...METER AND GAUGE 8E 3 Meter Assembly W O TOD Rear View 825RW038 Legend 10 LCD Light 11 Illumination Light 12 Illumination Light 13 Illumination Light 14 Illumination Light...

Страница 1842: ...er Assembly W TOD Front View 825RW034 Legend 1 TOD Indicator 2 Tachometer 3 Warning Light Lens 4 Speedometer 5 Coolant Temperature Gauge Fuel Gauge 6 Warning Light Lens 7 Reset Knob 8 A T Shift Indica...

Страница 1843: ...METER AND GAUGE 8E 5 Meter Assembly W TOD Rear View 825RW036 Legend 10 LCD Light 11 Illumination Light 12 Illumination Light 13 Illumination Light 14 Illumination Light...

Страница 1844: ...8E 6 METER AND GAUGE Table for Meter Gauge Connector Terminal Connections Meter Assembly W O TOD 1 825RW037...

Страница 1845: ...18 4WD indicator light 19 Ground Gauge 20 21 Winter drive indicator light 22 Oil pressure warning light 23 24 Air bag warning light 25 Power drive indicator light 26 27 Up shift indicator light 28 Tur...

Страница 1846: ...8E 8 METER AND GAUGE Meter Assembly W TOD 1 825RW035...

Страница 1847: ...in indicator light 20 Oil pressure warning light 21 Front 1 TOD 22 Front 2 TOD 23 Front 3 TOD 24 Lighting switch 25 Illumination controller 26 Starter switch 27 28 Winter drive indicator light 29 Powe...

Страница 1848: ...onnect the meter connectors to remove the meter assembly 5 825RW031 CAUTION The removed meter assembly should be placed upright or with its face side up Installation To install follow the removal step...

Страница 1849: ...the removal steps in the reverse order noting the following point 1 Tighten the vehicle speed sensor to the specified torque Torque 27 N m 20 lb ft Fuel Tank Unit Removal 1 Disconnect the battery grou...

Страница 1850: ...nnector to remove the multi meter 1 821RW036 Installation To install follow the removal steps in the revers order Ambient Sensor Removal 1 Disconnect the battery ground cable 2 Disconnect the connecto...

Страница 1851: ...METER AND GAUGE 8E 13 Main Data and Specifications Torque Specifications Application N m Lb Ft Lb In Vehicle Speed Sensor Fixing 27 20...

Страница 1852: ...nt Fender Panel 8F 16 Parts Location 8F 16 Removal 8F 16 Installation 8F 17 Body Mounting 8F 18 Parts Location 8F 18 Removal No 1 No 2 8F 18 Removal No 3 No 6 8F 19 Installation 8F 20 General Descript...

Страница 1853: ...73 Installation 8F 73 Tailgate Dove Tail Striker 8F 74 Adjustment 8F 74 Tailgate Frame Cover LH 8F 75 Parts Location 8F 75 Removal 8F 75 Installation 8F 75 Tailgate Frame Cover RH 8F 76 Removal 8F 76...

Страница 1854: ...will call out those fasteners that require a replacement after removal ISUZU will also call out the fasteners that require thread lockers or thread sealant UNLESS OTHERWISE SPECIFIED do not use supple...

Страница 1855: ...8F 4 BODY STRUCTURE Frame Dimensions 501RW013...

Страница 1856: ...ed by taking them out forward or backward after removing the two fixing bolts on either side Front Bumper Parts Location 601RX001 Legend 1 Front Bumper Assembly 2 Front Bumper Retainer Bolt 3 Clip 4 B...

Страница 1857: ...our bolts at each backbar 9 Remove front fog light assembly 10 Remove the front bumper slider 1 D Remove the two clips 4 and the two nuts 3 and release the claw from the washer 2 601RW009 Installation...

Страница 1858: ...Lower Bolts 6 Reinforce Upper Bolts 7 Rear Bumper Fascia Brackets 8 Rear Bumper Fascia Bracket Screws 9 Rear Bumper Assembly 10 Rear Bumper Side Covers 11 Mud Flaps 12 Rear Bumper Assembly Fixing Bolt...

Страница 1859: ...bumper fascia and take out the reinforce assembly 12 Remove backbars D Remove the three bolts from each backbar 13 Remove rear bumper slider brackets 4 D Remove the two clips 1 and two screws 3 and t...

Страница 1860: ...Refer to Rear Bumper in this section 2 Remove the three bolts 2 3 Remove rear bumper slider 1 690RS004 Installation To install follow the removal steps in reverse order noting the following points 1...

Страница 1861: ...When servicing these panels areas on which this material has been disturbed should be properly recoated with service type anti corrosion material Cowl Cover Parts Location 605RW003 Legend 1 Front Wipe...

Страница 1862: ...880RS001 4 Remove hood hinge bolts 3 D Before removing the hinges from the Engine hood 1 scribe a mark 2 showing location of the hinges to facilitate installation in the original position 610RS003 5 R...

Страница 1863: ...cowl cover D Refer to Cowl Cover in this section 2 Remove engine hood D Refer to Engine Hood in this section 3 Remove hinge fixing bolt and nut 4 Remove engine hood hinge 5 Remove hood end seal Instal...

Страница 1864: ...ssembly Removal 1 Remove hood lock control lever 2 Remove inner liner 3 Remove control cable D Remove the cable fixing clips from the body panel 4 Remove radiator grille D Refer to Radiator Grille And...

Страница 1865: ...its original position and check and see if the lock assembly and control lever work normally 2 Tighten the hood lock assembly fixing bolts to the specified torque Torque 10 N m 87 lb in Radiator Gril...

Страница 1866: ...4 Remove front end lower panel D Remove two fixing bolts and remove the panel from the fender Installation To install follow the removal steps in reverse order noting the following point 1 Install th...

Страница 1867: ...4 Front Combination Lamp Assembly 5 Inner Liner Removal 1 Open the hood 2 Support the hood 3 Remove cowl cover D Refer to Cowl Cover in this section 4 Remove front combination lamp assembly D Disconne...

Страница 1868: ...ect ten fixing bolts and two nuts 605RW001 Installation To install follow the removal steps in the reverse order noting the following points 1 Tighten the front fender panel fixing bolts to the specif...

Страница 1869: ...ounting Parts Location 510RX001 Removal No 1 No 2 1 Remove the front bumper 2 Jack up the vehicle by the frame 3 Support the front side sill and rear axle with stands Further support the front jack up...

Страница 1870: ...over the floor carpet and hold the bolt in check not to turn D No 4 Remove the bolt from under the frame 5 Loosen the mounting bolts No 5 6 on either side 6 Remove the frame side mounting and washer...

Страница 1871: ...e the frame side mounting and washer 6 Gently lower the jack supporting the rear axle until the cab side mounting can be removed 7 Remove the cab side mounting D Be sure to use a splice bar around the...

Страница 1872: ...emoval installation and servicing procedures pertaining to the TROOPER body Each servicing instruction is applicable to all models of the TROOPER unless otherwise specifically mentioned For those diff...

Страница 1873: ...8F 22 BODY STRUCTURE Body Dimension Upper Body A10RW001...

Страница 1874: ...8F 23 BODY STRUCTURE A10RY00001...

Страница 1875: ...8F 24 BODY STRUCTURE A10RY00002...

Страница 1876: ...8F 25 BODY STRUCTURE A10RY00007...

Страница 1877: ...8F 26 BODY STRUCTURE Front Section A10RW003...

Страница 1878: ...8F 27 BODY STRUCTURE A10RW004...

Страница 1879: ...8F 28 BODY STRUCTURE Room Section A10RW016...

Страница 1880: ...8F 29 BODY STRUCTURE A10RW005...

Страница 1881: ...8F 30 BODY STRUCTURE A10RW006...

Страница 1882: ...8F 31 BODY STRUCTURE Rear Section A10RW007...

Страница 1883: ...8F 32 BODY STRUCTURE A10RW008...

Страница 1884: ...8F 33 BODY STRUCTURE Side Body A10RW018...

Страница 1885: ...8F 34 BODY STRUCTURE A10RW009...

Страница 1886: ...8F 35 BODY STRUCTURE A10RW017...

Страница 1887: ...8F 36 BODY STRUCTURE Window Glass A10RW010...

Страница 1888: ...8F 37 BODY STRUCTURE A10RW011...

Страница 1889: ...8F 38 BODY STRUCTURE A10RW012...

Страница 1890: ...8F 39 BODY STRUCTURE A10RW013...

Страница 1891: ...nt Assembly 8 Instrument Panel Passenger Lower Cover Assembly 9 Glove Box 10 Lower Cluster Assembly 11 Front Console Assembly 12 Instrument Panel Driver Lower Cover Assembly 13 Driver Knee Bolster Ass...

Страница 1892: ...screws 1 in order to disconnect the cigarette lighter 3 and the illumination 2 connectors 740RS014 4 Remove glove box D Remove the 2 fixing screws 740RT024 5 Remove instrument panel passenger lower co...

Страница 1893: ...lts on the SRS adjust bracket and the cross beam under the passenger inflator module CAUTION For precautions on installation or removal of SRS air bag system refer to Supplemental RestraintSystem SRS...

Страница 1894: ...lator module 3 and the 2 fixing nuts 1 and washers on the support bracket 4 then disengage the 2 clips in order to remove the passenger inflator module 827RS022 12 Remove instrument panel cluster asse...

Страница 1895: ...Control Cable in HVAC section 15 Remove radio assembly D Remove 2 fixing screws 16 Remove vent duct assembly D Remove 5 fixing screws 17 Remove instrument harness assembly D Remove the 4 fixing screws...

Страница 1896: ...ter grille Claws at 8 positions 9 Instrument panel assembly 2 bolts SRS adjust bracket cross beam A C control cable Unit side at 3 position Instrument harness connector Driver side 5 position assist s...

Страница 1897: ...ry ground cable 2 Remove instrument panel assembly D Refer to Instrument Panel Assembly in this section 3 Remove side support bracket assembly LH RH D Remove the 4 fixing bolts on both sides 4 Remove...

Страница 1898: ...rake pedal link and the brake switch and remove the 4 fixing bolts and the nuts on the bracket 310RS011 8 Remove steering support bracket assembly D Remove the 2 fixing bolts upper side 1 and the 3 fi...

Страница 1899: ...ge and put a marker on it 4 Remove door harness connection 2 D Pull the door harness grommet out in order to disconnect the harness connection 810RS001 5 Remove front door assembly Installation To ins...

Страница 1900: ...m Pin 2 Door Harness Connection 3 Rear Door Assembly 4 Hinge Bolt Removal 1 Disconnect the battery ground cable 2 Apply a setting mark on the body side hinge 3 Remove door check arm pin 1 630RS002 4 R...

Страница 1901: ...reverse order noting the following points 1 Align the door fitting to the body by refer to Body Dimensions in this section 2 Tighten the door hinge bolts to the specified torque Torque 34 N m 25 lb ft...

Страница 1902: ...or Rear Door 2 Door Trim Panel 3 Check Arm Assembly 4 Check Arm Pin Bracket 5 Check Arm Pin 6 Front or Center Pillar Removal 1 Disconnect the battery ground cable 2 Remove door trim panel D Refer to...

Страница 1903: ...check arm fixing nuts to the specified torque Torque 13 N m 113 lb in 3 Apply chassis grease to the check arm pin moving surface Front Window Regulator Glass And Glass Run Parts Location 631RS002 Lege...

Страница 1904: ...seen 631RS004 D Remove the glass fixing bolts from the window regulator 2 and lower thefront side of the glass When the front side of the glass comes off the glass run 3 turn the glass inside out and...

Страница 1905: ...inside of the vehicle A10RS023 2 Set the glass into the door panel with the front side of the glass lowered and insert the rear side of the glass into the glass run 1 Then insert the front side of th...

Страница 1906: ...indow Regulator Motor Connector 5 Door Trim Panel 6 Waterproof Sheet Removal 1 Disconnect the battery ground cable 2 Remove door trim panel D Refer to Rear Door Trim Panel in Exterior Interior Trim se...

Страница 1907: ...window regulator cable fixing clip 3 from the door panel if model is equipped with power windows D Remove the window regulator 7 fixing bolts 2 and pull the regulator out from the lower hole of the do...

Страница 1908: ...ivision 4 Sash Division Fixing Bolts 5 Door Trim Panel 6 Waterproof Sheet 7 Glass Removal 1 Disconnect the battery ground cable 2 Remove door trim panel 3 Remove waterproof sheet 4 Remove glass D Refe...

Страница 1909: ...l steps in the reverse order noting the following points 1 Apply soap and water to the fixed glass 2 Apply soap and water to the door groove and insert the glass run 3 to the frame from the corner in...

Страница 1910: ...l 1 Remove front door slash moulding D To avoid the weatherstrip 1 and pry the door sash moulding 2 out from the door panel 645RS002 Installation 1 Front door sash moulding D Assemble the edge portion...

Страница 1911: ...r upper moulding 4 Remove rear door corner moulding D Avoiding the weatherstrip 3 pry the moulding 2 out from the door frame 1 645RS004 Installation To install follow the removal steps in the reverse...

Страница 1912: ...r waist seal D Remove the fixing screw and pull out the waist seal 1 from the door frame while prying it up 631RS010 Installation To install follow the removal steps in the reverse order noting the fo...

Страница 1913: ...8F 62 BODY STRUCTURE Rear Door Waist Seal Parts Location 651RW013 Legend 1 Rear Door Waist Seal Removal and Installation Refer to Front Door Waist Seal in this section...

Страница 1914: ...nt Door Weatherstrip Parts Location 631RS008 Legend 1 Check Arm Pin 2 Bracket 3 Weather Strip 4 Clip Removal 1 Remove check arm pin 2 Remove front door weatherstrip D Pull the weatherstrip 1 out from...

Страница 1915: ...me groove when installing the front door weatherstrip 2 2 Apply the sealing adhesive 3 to the upper A portion of the door frame 1 and press it for installation after assembling the weatherstrip 2 631R...

Страница 1916: ...8F 65 BODY STRUCTURE Rear Door Weatherstrip Parts Location 655RS001 Legend 1 Check Arm Pin 2 Rear Door Weather Strip 3 Clip Removal and Installation Refer to Front Door Weatherstrip in this section...

Страница 1917: ...t door sill plate 3 Remove front door seal finisher 1 D Pull the finisher out from the body panel 635RS003 Installation To install follow the removal steps in the reverse order noting the following po...

Страница 1918: ...luggage side lower cover 3 Remove rear door seal finisher 1 D Pull the rear door seal finisher 1 out from the body panel 635RS003 Installation To install follow the removal steps in the reverse order...

Страница 1919: ...ssembly 5 Tailgate Trim Panel LH 6 Tailgate Assembly LH Removal 1 Disconnect the battery ground cable 2 Remove tailgate time panel LH D Refer to Tailgate Trim Panel LH in Exterior Interior Trim sectio...

Страница 1920: ...he hinge fixing bolts 681RW007 Installation To install follow the removal steps in the reverse order noting the following points 1 Apply chassis grease to the tailgate hinge and the tailgate stopper m...

Страница 1921: ...ction 4 Rear Combination Light RH 5 Tailgate Fixing Bolt 6 Tailgate Hinge Removal 1 Disconnect the battery ground cable 2 Remove rear combination light RH 3 Remove tailgate trim panel RH D Refer to Ta...

Страница 1922: ...nge and remove the hinge fixing bolts 681RW006 Installation To install follow the removal steps in the reverse order noting the following point 1 Apply chassis grease to the tailgate hinge moving surf...

Страница 1923: ...Torque 12 N m 104 lb in Tailgate Stopper Assembly Parts Location 683RS010 Legend 1 Tailgate 2 Rear Bumper 3 Tailgate Stopper Assembly Removal 1 Remove tailgate stopper assembly D Remove the five bolts...

Страница 1924: ...umper 5 Tailgate LH Removal 1 Remove tailgate dove tail D Remove the two bolts from each side Installation To install follow the removal steps in the reverse order nothing the following points 1 Apply...

Страница 1925: ...Dove Tail Striker Adjustment 683RS012 1 Loosen the striker bolts 2 Tap with a plastic hammer to align D Gaps between Dove Tail Striker 2 and bracket 1 are 0 mm No clearance 683RS013 3 Tighten striker...

Страница 1926: ...er 2 out D Disconnect the washer tube 1 at the nozzle and pull the washer tube out from the frame cover 2 D Disconnect the rear defogger and pull the harness from the cover 684RW002 Installation To in...

Страница 1927: ...me cover out from the tailgate frame 684RS011 Installation To install follow the removal steps in the reverse order noting the following points 1 Hit the lower A edge portion 2 of the tailgate frame c...

Страница 1928: ...e Sash Trim Cover Removal 1 Remove tailgate sash trim cover 1 D Pry the tailgate trim cover retainers free from the tailgate panel 684RS013 Installation 1 Tailgate sash trim cover 1 D Insert the trim...

Страница 1929: ...weatherstrip 1 D Pry the tailgate outer weatherstrip clips 2 free from the body panel 682RS002 Installation To install follow the removal steps in the reverse order noting the following point 1 Insert...

Страница 1930: ...herstrip out from the tailgate panel Installation 1 Tailgate center weatherstrip 1 D Start assembling at the A portion 682RW006 D Clean the tailgate center weatherstrip 4 adhesive tape 2 and the butyl...

Страница 1931: ...p D Pull the tailgate main weatherstrip out from the body panel Installation 1 Tailgate main weatherstrip D Align the A and B positions to the corners of the body panel Install the tailgate main weath...

Страница 1932: ...tire 2 Remove spare tire carrier by using spare tire carrier nut wrench J 34355 530RS002 Installation 1 Install the spare tire carrier D Tighten the carrier fixing bolts to the specified torque Torque...

Страница 1933: ...unvisor Holder 9 Rear View Mirror 10 Multi Meter Removal 1 Disconnect the battery ground cable 2 Remove interior trim panels D Refer to the Exterior Interior Trim section 3 Remove dome light D Remove...

Страница 1934: ...ove it D Disconnect the vanity mirror illumination connector 743RS006 8 Remove sun roof finisher W Sun roof 9 Remove headlining D Remove the headlining fixing clips Installation To install follow the...

Страница 1935: ...10 Rear Pillar Upper Reinforcement 11 Rear Outer Roof Rail 12 Roof Panel 13 Grommet Removal 1 Disconnect the battery ground cable 2 Remove rear roof trim cover D Refer to Luggage Side and Quarter Uppe...

Страница 1936: ...off the adhesive tape of the washer to install the nylon washer to the air deflector 3 667RW004 3 Install the air deflector 2 to the roof by referring to the specified values shown in the illustratio...

Страница 1937: ...he battery ground cable 2 Remove roof moulding 3 Remove roof end moulding D Remove the sealing adhesive and the adhesive tape of the roof end moulding from the panel using a knife or scraper while you...

Страница 1938: ...them is within the specified values Securely fix it with the adhesive tape 4 and sealing adhesive 5 645RW001 3 Install the roof moulding 9 D Assemble the windshield side moulding upper clip 8 to the r...

Страница 1939: ...Removal 1 Disconnect the battery ground cable 2 Remove windshield wiper D Refer to Windshield Wipper Arm Blade in Wiper Washer System section 3 Remove front cowl cover D Refer to Cowl Cover in this s...

Страница 1940: ...ntire circumference of the windshield glass D Clean the remaining adhesive caulking material from the area of the body which holds the windshield 8 Remove windshield upper moulding D Taking notice of...

Страница 1941: ...on where sealing adhesive is additionally filled 5 Windshield 6 Cowl Upper Rail 7 Cowl Upper Panel 8 Body Primer 9 Roof Panel 10 Sealing Adhesive 11 Windshield Upper Moulding 12 Moulding Clip 13 Front...

Страница 1942: ...E 3 Install the windshield upper moulding 1 D Peel off the adhesive tape 2 and install the moulding to the fixed position of the windshield 3 D Always use new upper moulding 1 607RS005 4 Install the w...

Страница 1943: ...side seal 6 Install the windshield support 2 631RS014 D Apply a sealing adhesive 4 to the circumference of the windshield 5 D Apply the sealing adhesive to the frange portion of the cowl upper rail D...

Страница 1944: ...e rear quarter upper trim panel D Refer to Laggage Side and Quarter Upper Trim Cover in Exterior Interior Trim section 3 Remove ventilation assembly 4 Remove valve assembly D Refer to Ventilation Asse...

Страница 1945: ...the A clip portion D Insert the fixing clip on the side glass into the body panel D Push the side glass against the body panel and bond them D Cure the adhesive at a temperature of 20 30 C 68 86 F fo...

Страница 1946: ...Glass Moulding 5 Clip 6 Body Panel Removal 1 Remove battery ground cable 2 Remove tailgate trim panel 3 Remove tailgate sash trim cover RH only 4 Remove the tailgate frame cover D Refer to Tailgate F...

Страница 1947: ...gate glass and PCV primer to the glass moulding 1 D Apply a sealing adhesive to the circumference of the tailgate glass as shown D Insert the clip of the tailgate glass A portion into the tailgate pan...

Страница 1948: ...8F 97 BODY STRUCTURE Main Data and Specifications Torque Specifications E10RW001...

Страница 1949: ...8F 98 BODY STRUCTURE E10RW002...

Страница 1950: ...8F 99 BODY STRUCTURE E10RX004...

Страница 1951: ...8F 100 BODY STRUCTURE E10RX005...

Страница 1952: ...8F 101 BODY STRUCTURE E10RW005...

Страница 1953: ...8F 102 BODY STRUCTURE E10RW001...

Страница 1954: ...8F 103 BODY STRUCTURE E10RX001...

Страница 1955: ...8F 104 BODY STRUCTURE E10RX002...

Страница 1956: ...8F 105 BODY STRUCTURE E10RX003...

Страница 1957: ...8F 106 BODY STRUCTURE E10RS010...

Страница 1958: ...8F 107 BODY STRUCTURE Special Tools ILLUSTRATION TOOL NO TOOL NAME J 34355 Spare Tire Carrier Nut Wrench...

Страница 1959: ...llation 8G 19 Main Data and Specifications 8G 19 Service Precaution WARNING THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM SRS REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMI...

Страница 1960: ...Remove the cover fixing screw from the rear inner cover if this model is equipped with the power seats 4 Remove the door sill plate 5 Remove the rear seat foot rest D Refer to the Rear Seat Foot Rest...

Страница 1961: ...asher 2 Head Rest 3 Seat Back Assembly 4 Back Board Assembly 5 Reclining Device 6 Trim Cover 7 Guide Holder 8 Pad Frame Assembly 9 Slide Cover 10 Reclining Knob 11 Dial W Height Adjuster 12 Lock Sprin...

Страница 1962: ...embly D Open the armrest fastener and remove the armrest fixing bolt 750RS004 6 Remove the trim cover 7 Remove the pad and frame assembly 8 Remove the hinge cover 9 Remove the back board assembly 3 D...

Страница 1963: ...e wire 4 and remove the fixing bolts 750RW006 D Remove the seat belt buckle assembly 16 Remove the height adjuster 17 Remove the spacer W O height adjuster 18 Remove the seat cushion assembly 19 Remov...

Страница 1964: ...se switches to move the seat to desired position independent of the position of the starter switch Disassembled View 750RS011 Legend 1 Reclining Device 2 Inner Cover 3 Rear Cover 4 Armrest Assembly 5...

Страница 1965: ...the cover from the reclining device 2 750RS012 6 Remove the front cover 7 Remove the front lower cover 8 Remove the rear cover 9 Remove the outer cover D Disconnect the switch connectors and remove t...

Страница 1966: ...ng device connectors 750RW009 17 Remove the seat back assembly 18 Remove the guide holder 8 D Remove the trim cover fixing hog rings 9 from the backside of the seat back assembly D Hold the tip end of...

Страница 1967: ...30 Remove the pad assembly Reassembly To reassemble follow the disassembly steps in the reverse order noting the following point 1 Tighten the fixing bolts to the specified torque D Refer to the Torqu...

Страница 1968: ...tor Rear Tilt Motor Slide Motor Recliner Motor Parts Location 750RS027 Legend 1 Tilt Motor 2 Slide Motor 3 Tilt Motor 750RS028 Legend 4 Recliner Motor Removal and Installation Refer to the Power Seat...

Страница 1969: ...t built in the seat back and cushion is switched on to warm the seats To prevent the seats from being overheated the circuit is fitted with a thermostat Seat Heater Switch Removal and Installation Ref...

Страница 1970: ...Cover Removal 1 Unlock the rear seat 1 lock to remove it 2 Remove the mounting bracket cover 3 Remove the fixing bolts 755RS002 4 Remove the rear seat assembly Installation To install follow the remo...

Страница 1971: ...mbly 10 Band Hook Cover 11 Trim Cover 12 Pad Frame Assembly 13 Release Knob 14 Connecting Shaft 15 Release Rod 16 Linkage Bush 17 Device Cover 18 Trim Cover 19 Seat Lock Cover 20 Rear Seat Belt Buckle...

Страница 1972: ...and remove the fixing nuts 11 Remove the armrest set bracket 12 Remove the armrest board 13 Remove the trim cover D Remove the trim cover fixing hog rings from the backside of the seat back D With cl...

Страница 1973: ...s 1 Tighten the reclining device fixing bolts to the specified torque Torque 27 N m 20 lb ft 2 Loosen the rubber stopper lock nut 1 Adjust the stopper 3 so there is no clearance between the bottom of...

Страница 1974: ...ssembly 5 Seat Back Assembly 6 Release Knob 7 Release Rod 8 Device Cover 9 Linkage Bush 10 Reclining Device 11 Connecting Shaft 12 Seat Cushion Assembly 13 Connecting Link 14 Seat Lock Cover 15 Rear S...

Страница 1975: ...se attention paid to the hog rings and wire which connect the trim cover and the pad and frame assembly remove the trim cover as you turn it up 750RW011 10 Remove the pad frame assembly 11 Remove the...

Страница 1976: ...orque 27 N m 20 lb ft 2 Loosen the rubber stopper lock nut 1 and adjust the stopper rubber 3 so there is no clearance between the bottom of the stopper and the carpet 2 while ensuring the rear seat is...

Страница 1977: ...Remove the foot rest pad 676RS002 2 Remove the fixing nut 3 Remove the rear seat foot rest Installation To install follow the removal steps in the reverse order Main Data and Specifications Torque Sp...

Страница 1978: ...8G 20 SEATS E10RW008...

Страница 1979: ...Parts 8H 14 Removal 8H 14 Installation 8H 15 Tailgate Inside Lock Knob 8H 16 Removal 8H 16 Installation 8H 16 Tailgate Outside Handle and or Tailgate Lock Cylinder 8H 17 Tailgate Outside Handle and o...

Страница 1980: ...will also call out the fasteners that require thread lockers or thread sealant UNLESS OTHERWISE SPECIFIED do not use supplemental coatings Paints greases or other corrosion inhibitors on threaded fas...

Страница 1981: ...oor lock assembly 632RS004 Legend 1 To Inside Lock Knob 2 Door Lock Assembly 3 To Actuator 4 Door Lock Switch Connector 5 To Inside Handle 6 Outside Handle Installation To install follow the removal s...

Страница 1982: ...d Parts 632RS006 Legend 1 Door Trim Panel 2 Waterproof Sheet 3 Outside Handle 4 Door Lock Cylinder 5 Clip 6 Key Switch W Anti Theft Removal 1 Disconnect the battery ground cable 2 Remove the door trim...

Страница 1983: ...h connector w anti theft to remove the outside handle 632RS005 Legend 1 Outside Handle 2 To Door Lock Assembly 3 Key Switch Connector 5 Remove the key Switch 632RS007 Legend 1 Outside Handle 2 Lock Cy...

Страница 1984: ...r the anti theft system be sure to install the push rod 3 of key switch while pressing it to the door lock cylinder 5 so that there is no continuity between the key switch 4 side connector terminal No...

Страница 1985: ...and Associated Parts 652RS001 Legend 1 Door Trim Panel 2 Waterproof Sheet 3 Door Lock Assembly Removal 1 Disconnect the battery ground cable 2 Remove the door trim panel 3 Remove the waterproof sheet...

Страница 1986: ...ndle 2 To Inside Lock Knob 3 To Inside Handle 4 To Actuator Installation To install follow the removal steps in the reverse order noting the following points 1 Apply chassis grease to the lock assembl...

Страница 1987: ...rproof Sheet 3 Outside Handle Removal 1 Disconnect the battery ground cable 2 Remove the door trim panel 3 Remove the waterproof sheet D Refer to the Rear Window Regulator And Glass in Body Structure...

Страница 1988: ...perates smoothly Rear Door Inside Lock Knob Link Removal 1 Disconnect the battery ground cable 2 Remove the door trim panel 3 3 Remove the waterproof sheet 2 D Refer to the Rear Window Regulator And G...

Страница 1989: ...oor Trim Panel in Exterior Interior Trim section 3 Turn the door inside lock knob counterclockwise and then remove the door inside lock knob 2 632RS011 Installation To install follow the removal steps...

Страница 1990: ...Waterproof Sheet 3 Tailgate Lock Assembly Removal 1 Disconnect the battery ground cable 2 Remove the tailgate trim panel LH D Refer to the Tailgate Trim Panel LH in Exterior Interior Trim section 3 Ta...

Страница 1991: ...To Inside Lock Knob 2 To Actuator Installation To install follow the removal steps in the reverse order noting the following points 1 Apply chassis grease to the lock assembly and striker moving surfa...

Страница 1992: ...al 4 Clip 5 Screw 6 Tailgate Lock Assembly RH Removal 1 Disconnect the battery ground cable 2 Remove the tailgate trim panel RH D Refer to Tailgate Trim Panel RH in Exterior Interior Trim section 3 Pe...

Страница 1993: ...ation To install follow the removal steps in the reverse order noting the following points 1 Apply chassis grease to the lock assembly and striker moving surface 2 Tighten the tailgate lock assembly f...

Страница 1994: ...Remove the tailgate trim panel LH 2 D Refer to the Tailgate Trim Panel LH in Exterior Interior Trim section 3 Take care of cushion to turn the lock knob counterclockwise and then remove the tailgate...

Страница 1995: ...Associated Parts 684RW003 Legend 1 Tailgate Trim Panel LH 2 Waterproof Sheet 3 Grommet 4 Tailgate Lock Cylinder 5 Tailgate Outside Handle 6 Key Switch Removal 1 Disconnect the battery ground cable 2 R...

Страница 1996: ...nder fixing bolt 2 to remove the tailgate lock cylinder 683RS008 Installation To install follow the removal steps in the reverse order noting the following points 1 For the anti theft system install t...

Страница 1997: ...om suppliers If key codes are not available from records or tags the key code can be obtained from the right hand door lock cylinder if lock has not been replaced Lock cylinders supplied by the factor...

Страница 1998: ...oor lock switch or the front passenger s door lock switch is turned on current flows for about one second to the door lock actuator of each door connected in parallel with the front door lock power wi...

Страница 1999: ...e removal steps in the reverse order Tailgate Lock Actuator Removal 1 Refer to the Tailgate Lock Assembly removal procedure in this section 2 Remove the tailgate lock actuator 1 632RY00002 Tailgate Lo...

Страница 2000: ...o activate the detect switch by the starter key Anti theft Keyless Entry Control Unit Removal 1 Disconnect the battery ground cable 2 Remove the front console assembly D Refer to the Instrument Panel...

Страница 2001: ...theft Horn Removal 1 Disconnect the battery ground cable 2 Disconnect the connector and remove the fixing bolt to remove the anti theft horn 1 828RS007 Anti Theft Horn Installation To install follow...

Страница 2002: ...1 Is the action complete Go to Step 3 Go to Step 1 3 Close the driver s side door and then open it two times NOTE This step must be carried out within ten seconds after step 2 Is the action complete...

Страница 2003: ...door 3 Insert the key into the starter switch Is the action complete Go to Step 2 Go to Step 1 2 Turn the starter switch to ACC position and then to OFF position three times NOTE This step must be ca...

Страница 2004: ...Step 1 Anti theft Keyless Entry Control Unit Transmitter Replacement Anti theft Keyless Entry Control Unit Replacement 1 Remove and install the control unit D Refer to Anti theft Keyless Entry Contro...

Страница 2005: ...ock Assembly Fixing Screws 7 61 Front Outside Handle and Key Switch Fixing Bolts 9 78 Rear Door Lock Assembly Fixing Screws 7 61 Rear Outside Handle Fixing Bolts 9 78 Tailgate Lock Assembly LH Fixing...

Страница 2006: ...AS A SUPPLEMENTAL RESTRAINT SYSTEM SRS REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING WHEN...

Страница 2007: ...therstrip 2 Sun Roof Glass 3 Decoration Cover 4 Sun Roof Shim Removal 1 Open the sun roof and pull the sun roof weatherstrip out from the roof panel 2 Disconnect the battery ground cable 3 Close the s...

Страница 2008: ...o install the sun roof weatherstrip so that the white marking location 4 of the weatherstrip is on the front side of the vehicle 665RW016 3 Temporarily install the glass to the sun roof frame 4 Open a...

Страница 2009: ...P Sun Roof Deflector Removal 1 Open the sun roof 2 Remove the fixing screws 2 to remove the sun roof deflector 1 665RS006 Installation To install follow the removal steps in the reverse order Sunshade...

Страница 2010: ...of glass 2 to remove the sunshade stopper 3 Remove the sun roof deflector D Refer to the Sun Roof Deflector in this section 4 Open the sun roof completely 5 Remove the sunshade guide rail stopper 5 an...

Страница 2011: ...Drain Hose 2 Sun Roof Frame Complete Assembly 3 Headlining 4 Sun Roof Drain Hose Removal 1 Disconnect the battery ground cable 2 Remove the headlining D Refer to the Headlining in Body Structure secti...

Страница 2012: ...ame complete loosen the sun roof glass fixing nuts and adjust the sun roof glass setting position D Refer to the Sun Roof Glass in this section Disassembled View 665RW035 Legend 1 Sunshade 2 Sun Roof...

Страница 2013: ...out of the grommet 3 D At this time the inner cable 4 remains on the frame assembly 10 Remove the sun roof frame assembly 665RS012 Reassembly To reassembly follow the disassembly steps in the reverse...

Страница 2014: ...ips Taking care not to allow the body panel grommet to be removed together with the hose pull the drain hose only to the inside of the vehicle The string should be kept as it is Installation To instal...

Страница 2015: ...er Removal 1 Disconnect the battery ground cable 2 Remove the rear fender inner liner 3 Remove the headlining D Refer to the Headlining in Body Structure section 4 Disconnect the drive hose at the fra...

Страница 2016: ...uting cut the leading edge so that the protrusion is within 50 mm 2 0 in Sun Roof Switch General Description Sun roof operation can be controlled by pushing continuously the sun roof switch to activat...

Страница 2017: ...attery ground cable 2 Remove the headlining 2 D Refer to the Headlining in Body Structure section 3 Disconnect the connector and remove three nuts and two screws to remove the sun roof motor 1 665RW03...

Страница 2018: ...SUN ROOF CONVERTIBLE TOP 8I 13 Main Data and Specifications Torque Specifications Application N m Lb Ft Lb In Sun Roof Frame Complete Assembly Fixing Bolts 10 87 Sun Roof Glass Fixing Screws 10 87...

Страница 2019: ...t Pillar Trim Cover 8J 19 Front Pillar Trim Cover and Associated Parts 8J 19 Removal 8J 19 Installation 8J 20 Center Pillar Assist Grip 8J 20 Parts Location 8J 20 Removal and Installation 8J 20 Assist...

Страница 2020: ...PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING WHEN YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS WIRING REFER TO THE SRS SERVICE INFORMATION FAILURE TO FOLLO...

Страница 2021: ...ps of the trim panel D Take care not to damage the harness and the controller on the back of the trim panel 643RS007 Installation To install follow the removal steps in the reverse order noting the fo...

Страница 2022: ...moval 1 Disconnect the battery ground cable 2 Remove the shift knob M T transfer knob 4x4 only 3 Remove the front console assembly D Remove four fixing screws and disconnect the switch connectors 4 Re...

Страница 2023: ...sembly 2 D Remove two fixing screws on the front side Open the rear cover remove two nuts then the center console assembly D Remove the rear heater duct 1 from the center console 745RS005 Installation...

Страница 2024: ...Window Switch 2 Door Mirror Cover Tweeter 3 Door Wood Panel 4 Door Trim Panel 5 Courtesy Light 6 Front Speaker 7 Speaker Cover 8 Regulator Handle 9 Inside Handle Fixing Screw 10 Inside Handle 11 Hook...

Страница 2025: ...switch connector 825RW045 5 Remove the speaker cover 6 Remove the front speaker D Remove the front speaker fixing screws in order to disconnect the speaker connector 7 Remove the inside handle fixing...

Страница 2026: ...007 D Disconnect the courtesy light connector 13 to lift the door trim panel 14 and unlock the engagement of the waist seal 12 section Then pass the inside handle 11 through the mounting hole of the t...

Страница 2027: ...im panel and assemble the trim panel Engage seven clips 8 into the door panel Also connect the courtesy light connector 5 and leave the connectors of the speaker 7 tweeter 9 and power window 3 drawn o...

Страница 2028: ...egend 1 Power Window Switch 2 Door Wood Panel 3 Courtesy Light 4 Door Trim Panel 5 Washer 6 Clip 7 Regulator Handle 8 Inside Handle Fixing Screw 9 Inside Handle Removal 1 Disconnect the battery ground...

Страница 2029: ...door with the inside handle 632RW002 5 Remove the door trim panel 6 D Remove two fixing screws 8 to take off seven clips 7 from the door panel 655RS004 D Unplug the courtesy light connector to lift t...

Страница 2030: ...nto the door panel Also connect the courtesy light connector Leave the connector of the power window drawn out to its prescribed position so that it will not caught 3 Put back the inside handle 3 to t...

Страница 2031: ...Removal 1 Remove the door trim panel 1 D Refer to the Front Rear Door Trim Panel in this section 2 Remove the door wood panel assembly 2 D Remove four door wood panel assembly fixing screws and washer...

Страница 2032: ...Remove the door mirror connector 4 Remove the door mirror Installation To install follow the removal steps in the reverse order noting the following points 1 When you install the door mirror install...

Страница 2033: ...r 5 Luggage Side Trim Cover 6 Rear End Floor Trim Cover 7 Luggage Side Cap 8 Speaker Grille 9 Rear Speaker 10 Clip 11 Luggage Room Light 12 Rear Roof Trim Cover Removal 1 Disconnect the battery ground...

Страница 2034: ...m cover retainers free from the body panel 666RS001 8 Remove the speaker grille 687RS003 9 Remove the rear speaker D Remove the rear speaker fixing screws and disconnect the connector 10 Remove the re...

Страница 2035: ...lar and Roof Side Trim Cover Center Pillar Roof Side Trim Cover and Associated Parts 643RW003 Legend 1 Roof Side Trim Cover 2 Front Pillar Trim Cover 3 Assist Grip RH only 4 Adjust Shoulder Anchor Ass...

Страница 2036: ...hen slide the trim cover downward 643RS003 4 Remove the front seat belt anchor bolt cover 3 and the anchor bolt 4 760RW006 5 Remove the center pillar upper trim cover 6 D Turn up the finisher 5 and pr...

Страница 2037: ...ing the following point 1 Install the seat belt anchor bolts to the specified torque Torque 39 N m 29 lb ft Front Pillar Trim Cover Front Pillar Trim Cover and Associated Parts 743RS003 Legend 1 Roof...

Страница 2038: ...trim cover retainers free from the body panel 635RW001 Installation To install follow the removal steps in the reverse order Center Pillar Assist Grip Parts Location 743RS004 Legend 1 Center Pillar A...

Страница 2039: ...EXTERIOR INTERIOR TRIM 8J 21 Assist Grip Parts Location 743RS005 Legend 1 Assist Grip Removal and Installation Refer to the Center Pillar and Roof Side Trim Cover in this section...

Страница 2040: ...sembly 8 Fuel Filler Lid Opener 9 Front Seat RH 10 Center Pillar Lower Trim Cover 11 Rear Door Sill Plate RH 12 Luggage Side Trim Panel RH Removal 1 Disconnect the battery ground cable 2 Remove the fr...

Страница 2041: ...pull out the cable toward the fuel filter lid Installation To install follow the removal steps in the reverse order noting the following points 1 Insert the opener cable 2 into the body panel 1 secure...

Страница 2042: ...rotector 2 Inner Liner 3 Spare Nut 4 Fixing Screw 5 Rocker Protector 6 Outer Side Panel 7 Outer Wheel House Panel 8 Fixing Clip 9 Outer Rocker Panel 10 Door Panel 11 Front Rocker Protector 12 Clip W R...

Страница 2043: ...oor Wheel Opening Extension Assembly Removal 1 Remove the front rocker protector assembly D Loosen and pull clips and remove the front rocker protector assembly 2 Remove the rear rocker protector asse...

Страница 2044: ...ge riveted portions Disengage three clips peel off the bonded portions with two double surface adhesive tape and the rear door wheel opening extension assembly Installation To install follow the remov...

Страница 2045: ...front bumper assembly D Disconnect the front fog light connector and remove two bolts from both sides of the front bumper 2 Remove the front bumper slider 1 D Remove two clips 4 and two nuts 3 release...

Страница 2046: ...the ventilation assembly retainers free from the body panel 641RS002 2 Remove the outlet valve assembly Installation 1 Install the outlet valve assembly D Insert the upper and lower catches of the ou...

Страница 2047: ...1 Tailgate Trim Panel LH 2 Clip 3 Tailgate Panel 4 Cap and Screw Removal 1 Disconnect the battery ground cable 2 Remove the cap and screw 3 Remove the tailgate trim panel LH D Pry the trim panel retai...

Страница 2048: ...lgate Trim Panel Removal 1 Disconnect the battery ground cable 2 Remove the tailgate trim panel RH D Pry trim panel retainer free from the tailgate panel 684RS003 Installation 1 Install the trim panel...

Страница 2049: ...lips which connect the floor carpet and the luggage floor box cover 3 Remove the luggage floor box Installation To install follow the removal steps in the reverse order Rope Hook Set Rope Hook Set and...

Страница 2050: ...shift lever knob D Disconnect the seat heater switch connectors if so equipped D Disconnect the door mirror switch connectors D Disconnect the power winter switch connectors A T only 3 Remove the door...

Страница 2051: ...e passenger s power window switches are shut off So even if these switches are operated the power window motor will not operate Power Window Switch Removal and Installation Driver Seat Side Removal 1...

Страница 2052: ...connect the battery ground cable 2 Remove the window regulator assembly 1 D Refer to Front Window Regulator Glass and Glass Run in Body Structure section 3 Remove the power window motor 2 D Remove thr...

Страница 2053: ...EXTERIOR INTERIOR TRIM 8J 35 Main Data and Specifications Torque Specifications Application N m Lb Ft Lb In Door Mirror Fixing Bolts 8 69 Seat Belt Anchor Bolts 39 29 Hook Fixing Bolt 13 113...

Страница 2054: ...IS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM SRS REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFORMING SERVICE ON OR NEAR THE SRS COMPONENTS OR THE SRS...

Страница 2055: ...ront seat belt anchor bolt cover and anchor bolt Upper Side D Refer to Center Pillar and Roof Side Trim Cover in Exterior Interior Trim section 5 Remove the seat belt lower anchor bolt and screw and t...

Страница 2056: ...ts normal operation CAUTION Do not disassemble the retractor Installation To install follow the removal steps in the reverse order noting the following points CAUTION The front seat belt for 99model i...

Страница 2057: ...sure it is not locked within 15 in any directions and it remains locked at 45 or larger 2 ELR lock check D When the seat belt is drawn slowly with the retractor installed make sure it is not locked A...

Страница 2058: ...at Lock Cover Removal 1 Remove the catch portions 2 3 of the seat lock assembly 4 from the cover and then remove the seat lock cover 1 760RW016 2 Remove the rear seat buckle assembly Installation 1 Fi...

Страница 2059: ...t lock fixing bolts to the specified torque Torque 42 N m 31 lb ft Rear Seat Lock Assembly Bench Type Removal 1 Remove the seat lock cover 3 2 Remove the rear seat belt buckle assembly 1 3 Disconnect...

Страница 2060: ...at three places on the luggage floor panel Remove the center plug from the floor panel Install the bracket to the hole where the plug is removed Alternatively the bracket may be installed in the right...

Страница 2061: ...pplication N m Lb Ft Lb In Front Seat Belt Anchor Bolts 39 29 Rear Seat Belt Anchor Bolts 39 29 Front Seat Buckle Anchor Bolt 39 29 Rear Seat Buckle Anchor Bolt 39 29 Rear Seat Lock Fixing Bolts 42 31...

Страница 2062: ...and Specifications 9J 42 Service Precaution WARNING THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM SRS REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE PERFO...

Страница 2063: ...t require it If the above conditions are not followed parts or system damage could result Restraint Devices 827RW006 Legend 1 Deployed Air Bag 2 Knee Bolster 3 Seat Belt The Supplemental Restraint Sys...

Страница 2064: ...ir bag assembly which will cause deployment of the air bags in the event of a frontal crash of sufficient force up to 30 degrees off the centerline of the vehicle The air bag assemblies are only suppl...

Страница 2065: ...WARNING DURING SERVICE PROCEDURES BE VERY CAREFUL WHEN HANDLING A SENSING AND DIAGNOSTIC MODULE SDM NEVER STRIKE OR JAR THE SDM NEVER POWER UP THE SRS WHEN THE SDM IS NOT RIGIDLY ATTACHED TO THE VEHI...

Страница 2066: ...nition switch is at the ON or START positions with the SDM disconnected 827RW004 Legend 1 SDM 2 SRS Harness 3 Connector Position Assurance Air Bag Warning Lamp Ignition voltage is applied to the AIR B...

Страница 2067: ...iver air bag assembly is shorted in this way to help prevent unwanted deployment of the air bag when servicing the driver air bag assembly the steering column or other SRS components 827RS008 There is...

Страница 2068: ...iver air bag assembly circuit during the Initiator Assembly Resistance Test Driver Air Bag Assembly An assembly located in the steering wheel hub consisting of an inflatable bag an inflator and an ini...

Страница 2069: ...ostic trouble codes using the scan tool 1 Current diagnostic trouble codes Malfunctions that are presently being detected Current diagnostic trouble codes are stored in RAM Random Access Memory 2 Hist...

Страница 2070: ...d difference model year air bag assembly The air bag assembly has identification colors on the bar code label from 00 model as follows Yellow color for driver air bag assembly White color for passenge...

Страница 2071: ...FAILURE TO FOLLOW PROCEDURES COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT PERSONAL INJURY OR OTHERWISE UNNEEDED SRS REPAIRS The SDM in Driver Passenger SRS can maintain sufficient voltage to cause a d...

Страница 2072: ...bly to be thrown through the air in the unlikely event of an accidental deployment 827RV004 WARNING WHEN CARRYING A LIVE AIR BAG ASSEMBLY MAKE SURE THE BAG OPENING IS POINTED AWAY FROM YOU IN CASE OF...

Страница 2073: ...d be read fully before they are performed The following procedure requires use of J 42986 SRS deployment harness with appropriate pigtail adapter Do not attempt procedure without J 42986 adapter WARNI...

Страница 2074: ...ector functioning shorted and may result in nondeployment of the driver air bag assembly 12 Verify that the area around the driver air bag assembly is clear of all people and loose or flammable object...

Страница 2075: ...r source and that its two banana plugs have been shorted together by fully seating one banana plug into the other 25 Disconnect the pigtail adapter from the driver air bag assembly WARNING WHEN STORIN...

Страница 2076: ...that no loose or flammable objects are within the deployment area 7 Place the J 41497 on the bench vice This is necessary to provide sufficient stabilization of the fixture during deployment 8 Attach...

Страница 2077: ...WILL BE HOT DO NOT TOUCH THE METAL AREAS OF THE AIR BAG ASSEMBLY FOR ABOUT THIRTY MINUTES AFTER DEPLOYMENT IF THE DEPLOYED AIR BAG ASSEMBLY MUST BE MOVED BEFORE IT IS COOL WEAR GLOVES AND HANDLE BY T...

Страница 2078: ...R BAG WHEN A POWER SOURCE IS CONNECTED TO IT CONNECTING THE DEPLOYMENT WIRES TO THE POWER SOURCE SHOULD ALWAYS BE THE FINAL STEP IN THE AIR BAG ASSEMBLY DEPLOYMENT PROCEDURE FAILURE TO FOLLOW PROCEDUR...

Страница 2079: ...oves and safety glasses to protect your hands and eyes from possible irritation and heat when handling the deployed air bag assembly After an air bag assembly has been deployed the surface of the air...

Страница 2080: ...ESULT IN PERSONAL INJURY 37 Temporarily store the air bag assembly with the air bag opening facing up away from the surface upon which it rests Deployed Air Bag Assembly Handling Put on a pair of shop...

Страница 2081: ...river air bag assembly when it is connected at the top of the column to the SRS coil assembly Another small connector is used to substitute for the load of the driver air bag assembly and the SRS coil...

Страница 2082: ...pter will also give an idea of whether contact tension is sufficient helping to find an open or intermittent open due to poor terminal contact J 42986 SRS Deployment Tool 901RW106 The J 42986 SRS Depl...

Страница 2083: ...card with the Tech 2 the following steps must be performed 1 Insert the Isuzu 98 System PCMCIA card 1 into the Tech 2 5 2 Connect the SAE 16 19 adapter 3 to the DLC cable 4 3 Connect the DLC cable to...

Страница 2084: ...LEMENTAL RESTRAINT SYSTEM 9J 23 Operating Procedure The power up screen is displayed when you power up the tester with the Isuzu systems PCMCIA card Follow the operating procedure below 060RY027 060RW...

Страница 2085: ...ve key 1 Connect yellow 2 pin connector passenger air bag assembly 2 Install glove box assembly Refer to Passenger Air Bag Assembly Replacement in this section 3 Connect yellow 2 pin connector at the...

Страница 2086: ...cement only Verify replacement part numbers CAUTION Proper operation of the SDM and supplemental restraint system SRS requires that any repairs to the vehicle structure return it to its original produ...

Страница 2087: ...ENTAL RESTRAINT SYSTEM 9J 26 Installation To install the connector hold the socket insulator 1 and insert it The cover insulator slides and connector will be locked Do not hold the cover insulator 2 8...

Страница 2088: ...ONT OF THE VEHICLE SDM is specifically calibrated and is keyed to the SDM location SRS wiring harness Caution should be used to ensure proper location of the SDM The keying of the SDM to its location...

Страница 2089: ...SUPPLEMENTAL RESTRAINT SYSTEM 9J 28 5 Enable the SRS Refer to Enabling the SRS in this section 827RW026 Legend 1 SDM 2 SRS Harness 3 Connector Position Assurance...

Страница 2090: ...ING ALIVE AIR BAG ASSEMBLY ON A BENCH OR OTHER SURFACE ALWAYS FACE BAG AND TRIM COVER UP AWAY FROM THE SURFACE NEVER REST A STEERING COLUMN ASSEMBLY ON THE STEERING WHEEL WITH THE AIR BAG ASSEMBLY FAC...

Страница 2091: ...to specified sequence as shown in figure Torque 8 N m 69 lb in CAUTION Never use the air bag assembly from another vehicle and difference model year air bag assembly The air bag assembly has identific...

Страница 2092: ...CH OR OTHER SURFACE ALWAYS FACE BAG AND RIM COVER UP AWAY FROM THE SURFACE NEVER REST A STEERING COLUMN ASSEMBLY ON THE STEERING WHEEL WITH THE AIR BAG ASSEMBLY FACE DOWN AND COLUMN VERTICAL THIS IS N...

Страница 2093: ...l CAUTION Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel The steering shaft is designed as an ener...

Страница 2094: ...bly from another vehicle and difference model year air bag assembly The air bag assembly has identification colors on the bar code label from 00 model as follows Yellow color for driver air bag assemb...

Страница 2095: ...SSEMBLY ON A BENCH OR OTHER SURFACE ALWAYS FACE BAG AND RIM COVER UP AWAY FROM THE SURFACE NEVER REST A STEERING COLUMN ASSEMBLY ON THE STEERING WHEEL WITH THE AIR BAG ASSEMBLY FACE DOWN AND COLUMN VE...

Страница 2096: ...el in the direction of the shaft by using a hammer or other impact tools in an attempt to remove the steering wheel The steering shaft is designed as an energy absorbing unit 14 Remove the combination...

Страница 2097: ...nnect air bag to wiring harness connector NOTE Pass the lead wire through the tabs on the plastic cover wire protector of air to prevent lead wire from being pinches 827RT009 12 Install air bag into s...

Страница 2098: ...THER SURFACE ALWAYS FACE BAG AND RIM COVER UP AWAY FROM THE SURFACE NEVER REST A STEERING COLUMN ASSEMBLY ON THE STEERING WHEEL WITH THE AIR BAG ASSEMBLY FACE DOWN AND COLUMN VERTICAL THIS IS NECESSAR...

Страница 2099: ...t the wiring harness connectors located at the base of steering column CAUTION Never apply force to the steering wheel in direction of the shaft by using a hammer or other impact tools in an attempt t...

Страница 2100: ...the specified torque Torque 31 N m 23 lb ft 5 Install steering lock cylinder assembly 6 Connect shift lock cable For A T 7 Install cushion rubber 8 Install snap ring 9 Install the combination switch a...

Страница 2101: ...being pinched 827RT009 17 Install air bag into steering wheel and tighten bolts to specified sequence as shown in figure Torque 8 8 N m 78 lb in CAUTION Never use the air bag assembly from another veh...

Страница 2102: ...ASSEMBLY ON THE STEERING WHEEL WITH THE AIR BAG ASSEMBLY FACE DOWN AND COLUMN VERTICAL THIS IS NECESSARY SO THAT A FREE SPACE IS PROVIDED TO ALLOW THE AIR BAG ASSEMBLY TO EXPAND IN THE UNLIKELY EVENT...

Страница 2103: ...instrument panel assist side lower cover 10 Install glove box cover 11 Install glove box assembly with lid 12 Install ECM and SDM cover 13 Install rear console assembly and connect harness connector 1...

Страница 2104: ...71 Internal SDM Fault 9J1 40 Service Precaution WARNING THIS VEHICLE HAS A SUPPLEMENTAL RESTRAINT SYSTEM SRS REFER TO THE SRS COMPONENT AND WIRING LOCATION VIEW IN ORDER TO DETERMINE WHETHER YOU ARE...

Страница 2105: ...ere last cleared during service 1 Active Codes Faults that are presently detected this ignition cycle Active codes are stored in RAM Random Access Memory 2 History Codes All faults detected since the...

Страница 2106: ...l continually by repeated until ground is removed from terminal 4 of the DLC connector Two special codes exist when reading in the flash code mode Flash Code 12 and Flash Code 13 Flash Code 12 will al...

Страница 2107: ...S Diagnostic System Check after all repair or diagnostic procedures will ensure that the repair has been made correctly and that no other malfunctions exist Circuit Description When the ignition switc...

Страница 2108: ...ouble code s displayed Ignition switch OFF When DTC 71 is set go to DTC 71 Chart For all other history codes refer to Diagnostic Aids For that specific DTC A history DTC indicates the malfunction has...

Страница 2109: ...scan tool Clear Codes command If DTCs 51 53 are not indicated then DTC 71 is not existing DTCs 51 53 and 71 can not be cleared after a Clear Codes command is issued Chart Test Description Number s bel...

Страница 2110: ...to verify the need for SDM replacement 3 Ignition switch OFF 4 Reconnect all SRS components ensure all components are properly mounted 5 Ensure the ignition switch has been OFF for at least 15 seconds...

Страница 2111: ...em voltage to the Ignition 1 inputs terminals 12 The SDM responds by flashing the AIR BAG warning lamp 7 times If Ignition 1 is less than 9 volts the AIR BAG warning lamp will come ON solid with no DT...

Страница 2112: ...F Replace SDM Go to Step 5 Connect SDM securely to de activate shorting clip in SDM harness connector Go to Step 5 3 Using scan tool request SRS data list Is ignition more than 9 volts Go to Step 4 Ig...

Страница 2113: ...ll be still OFF solid with no DTCs set Chart Test description Number s below refer to step number s on the diagnostic chart 1 This test decides whether power is available to SDM warning lamp power fee...

Страница 2114: ...If ok then remove and inspect AIR BAG bulb Is bulb good Go to Step 5 Replace bulb Go to Step 6 4 1 Ignition switch OFF 2 Disconnect instrument meter cluster harness connector 3 Ignition switch ON 4 M...

Страница 2115: ...column and behind the glove box assembly 2 Disconnect SDM 3 Replace C 10 fuse 4 Ignition switch ON wait 10 seconds 5 Ignition switch OFF 6 Remove and inspection C 10 fuse Is fuse good Install C 10 fus...

Страница 2116: ...nnector terminal contact is above a specified value This test is run once each ignition cycle during the Resistance Measurement Test when 1 No higher priority faults are detected during Turn ON 2 Igni...

Страница 2117: ...ct the passenger air bag assembly yellow 2 pin connector located behind the glove box assembly 2 If ok reconnect the passenger air bag assembly 2 pin connector 3 Ignition switch ON Is DTC 15 current G...

Страница 2118: ...ector terminal contact is above a specified value This test is run once each ignition cycle during the Resistance Measurement Test when 1 No higher priority faults are detected during Turn ON 2 Igniti...

Страница 2119: ...air bag assembly yellow 2 pin connector located behind the glove box assembly 2 If ok reconnect the passenger air bag assembly 2 pin connector 3 Ignition switch ON Is DTC 16 Current Go to Step 5 Go t...

Страница 2120: ...inal 16 is above or equal to a specified value for 500 milliseconds during Continuous Monitoring Action Taken SDM turns ON the AIR BAG warning lamp and sets a diagnostic trouble code DTC Will Clear Wh...

Страница 2121: ...econnect the passenger air bag assembly 2 pin connector 3 Ignition switch ON Is DTC 17 current Go to Step 5 Go to Step 7 5 1 Ignition switch Off 2 Disconnect SRS coil and passenger air bag assembly ye...

Страница 2122: ...n once each ignition cycle and Continuous Monitoring Action Taken SDM turns ON the AIR BAG warning lamp and sets a diagnostic trouble code DTC Will Clear When This malfunction is no longer occurring a...

Страница 2123: ...ly 3 Leave driver air bag assembly connected 4 Connect SRS driver passenger load tool J 41433 and appropriate adapter to passenger air bag assembly harness connector 5 Ignition switch ON Is DTC 18 cur...

Страница 2124: ...the AIR BAG warning lamp and sets DTC 19 and also DTC 71 DTC Will Clear When The SDM is replaced DTC Chart Test Description Number s below refer to step number s on the diagnostic chart 2 This test d...

Страница 2125: ...passenger air bag assembly yellow 2 pin connector behind the glove box assembly 3 Leave driver air bag assembly connected 4 Connect SRS driver passenger load tool J 41433 and appropriate adapter to p...

Страница 2126: ...assembly harness wiring CKTs IB05 YEL and IB06 YEL BLK and connector terminal contact is above a specified value This test run once each ignition cycle during the Resistance Measurement Test when 1 No...

Страница 2127: ...t loop resistance Is driver resistance more than 3 7 ohms Go to Step 3 Go to Chart A 3 1 Ignition switch OFF 2 Disconnect SRS coil assembly yellow 2 pin connector located at base of steering column is...

Страница 2128: ...41433 on the top of steering column 4 Reconnect SRS coil assembly harness connector as the base of steering column 5 Ignition switch ON Is DTC 21 current Ignition switch OFF Replace SRS coil assembly...

Страница 2129: ...B06 YEL BLKand connector terminal contact is above a specified value This test is run once each ignition cycle during the Resistance Measurement Test when 1 No higher priority faults are detected duri...

Страница 2130: ...f steering column 2 If ok reconnect the SRS coil assembly yellow 2 pin connector 3 Ignition switch ON Is DTC 22 current Go to Step 5 Go to Step 8 5 1 Ignition switch OFF 2 Disconnect SRS coil and pass...

Страница 2131: ...Driver Bag Low is below a specified value DTC 24 will set Action Taken SDM turns ON the AIR BAG warning lamp and sets a diagnostic trouble code DTC Will Clear When The malfunction is no longer occurr...

Страница 2132: ...ch OFF 2 Disconnect SDM 3 Disconnect SRS driver passenger load tool 4 Measure resistance on SDM harness connector 3 to terminal 6 ground Does J 39200 display OL infinite Go to Step 5 Replace SRS harne...

Страница 2133: ...l Clear When The SDM is replaced DTC Chart Test Description Number s below refer to step number s on the diagnostic chart 2 This test determines whether the SDM is malfunctioning 3 This test isolates...

Страница 2134: ...harness connector 4 Ignition switch ON Is driver sense LO more than 3 5 volts Go to Step 4 Go to Step 6 4 1 Ignition switch OFF 2 Disconnect SDM 3 Disconnect SRS driver passenger load tool 4 Measure r...

Страница 2135: ...ets a diagnostic trouble code DTC Will Clear When The voltage difference between Driver Bag High terminal 3 and Driver Bag Low terminal 4 is below a specified value for 500 milliseconds during Continu...

Страница 2136: ...in connector located at the base of steering column and behind the glove box assembly 3 Connect SRS driver passenger load tool J 41433 and appropriate adapter to SRS coil and passenger air bag assembl...

Страница 2137: ...y deploying the air bags and causing DTC 51 to set DTC Will Set When The SDM detects a frontal crash up to 30 degrees off the centerline of the vehicle of sufficient force to warrant deployment of the...

Страница 2138: ...No 1 Was the SRS Diagnostic System Check performed Go to Step 2 Go to the SRS Diagnostic System Check 2 Ignition switch OFF Have air bag assemblies deployed Replace components and perform inspections...

Страница 2139: ...loyment situation in one or both air bag assemblies DTC Will Set When The SDM detects a frontal crash up to 30 degrees off the centerline of the vehicle of sufficient force to warrant deployment of th...

Страница 2140: ...INJURY Step Action Yes No 1 Was the SRS Diagnostic System Check performed Go to Step 2 Go to the SRS Diagnostic System Check 2 Ignition switch OFF Have air bag assembles deployed Replace components a...

Страница 2141: ...value and the output state does not match the commanded state of the lamp driver for 500 milliseconds DTC 61 is set DTC Will Set When Ignition 1 voltage is in the specified value and the output state...

Страница 2142: ...thin the AIR BAG warning lamp circuitry will set this diagnostic trouble code 2 These malfunctions are addressed in the SRS Diagnostic System Check via Chart B and Chart C 3 Failure to properly perfor...

Страница 2143: ...8 Arming sensor fault 9 Diagnostic current faults 10 DTC 19 11 DTC 25 12 DTC 51 13 DTC 53 DTC Will Set When Any of the above indicated malfunctions are detected by the SDM The malfunctions described a...

Страница 2144: ...as been set it is necessary to replace the SDM Setting DTC 19 and 25 or 51 or 53 will also cause DTC 71 to set When a scan tool CLEAR CODES command is issued and the malfunction is no longer present D...

Страница 2145: ...ed fasteners or fastener joint interfaces Generally such coatings adversely affect the fastener torque and the joint clamping force and may damage the fastener When you install fasteners use the corre...

Страница 2146: ...d on D When the brake pedal is pressed D When the clutch pedal is pressed M T D When the select lever is shifted to any position other than D 3 2 or L A T D When the cancel switch is operated D When t...

Страница 2147: ...e pedal arm becomes 0 5 to 1 0 mm 0 02 0 04 in 6 Tighten the lock nut 7 Connect the switch connector 310RW006 Clutch Switch Removal and Installation Refer to the Clutch Control removal and installatio...

Страница 2148: ...Refer to the Instrument Panel Assembly in Body Structure section 821RW024 5 Remove seven screws to remove the steering cowl 6 6 Disconnect the connector remove the screw 4 and then remove the starter...

Страница 2149: ...on 6 Disconnect the and push the lock from the side of the instrument panel cluster assembly to remove the cruise control main switch 4 821RW079 Installation To install follow the removal steps in the...

Страница 2150: ...IMES WITHIN 1 SECOND DIAGNOSIS IS ENABLED IN 130 SECONDS AFTER THE SWITCH OPERATED P0566 CRUISE CAN CEL CIRCUIT D D THE SWITCH CONTACT REMAINS ON FOR 40 SECONDS OR MORE D NOISES ARE GENERATED BY THE P...

Отзывы:

Нет отзывов

Похожие инструкции для 2000 Trooper UX

Бренд: Camcar Страницы: 6

MARTEN-FREE CAR

Бренд: Gardigo Страницы: 36

Бренд: Vauxhall Страницы: 177

Бренд: Toyota Страницы: 56

Бренд: Yakima Страницы: 12

Бренд: ULTIMATE SPEED Страницы: 21

Бренд: RAM Страницы: 496

Бренд: C-KO Страницы: 4

Бренд: KEKO Страницы: 13

Stealth 4191F Series

Бренд: Road Armor Страницы: 5

Quantum Wash'n'Wipe N30208

Бренд: National Cycle Страницы: 12

Бренд: Mazda Страницы: 1001

OVER DRIVE PolyPRO 3 Car Cover

Бренд: Classic Accessories Страницы: 2

Бренд: HUSKY LINERS Страницы: 4

Бренд: iOttie Страницы: 19

Бренд: Gator Страницы: 5

Бренд: Phonocar Страницы: 4

Бренд: ULTIMATE SPEED Страницы: 18

Бренды по названию

0 1 2 3 4 5 6 7 8 9 A B C D E F G H I J K L M N O P Q R S T U V W X Y Z

Популярные бренды

Загрузить еще бренды