Isuzu Frontera Service Manual 1999-2001
Complete official service manual for 1999-2001 Isuzu Frontera, with all the shop information to maintain, diagnostic, repair, refurbish/rebuild like professional mechanics.
Isuzu Frontera all models workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
MAKE: Isuzu
YEAR: 1999 2000 2001
MODEL: Frontera (UE) (a.k.a. Opel/Vauxhall/Holden Frontera)
PRODUCT DETAILS:
Total Pages: 7,070 pages
File Format: PDF (Windows & Mac & Linux)
Language: English
TABLE OF CONTENTS
GENERAL INFORMATION
General Information
Maintenance and Lubrication
HEATING, VENTILATION AND AIR CONDITIONING
HVAC System
STEERING
Power-Assisted System
SUSPENSION
Front Suspension
Rear Suspension
Wheel and Tire System
DRIVELINE/AXLE
Differential (Front)
Differential (Rear)
Driveline Control System
Drive Shaft System
Transfer Case
BRAKE
Brake Control System
Anti-Lock Brake System
Power-Assisted Brake System
Parking Brake System
ENGINE
Engine Mechanical
Engine Cooling
Engine Fuel
Engine Electrical
Ignition System
Starting and Charging System
Driveability and Emissions
Engine Exhaust
Engine Lubrication
Engine Speed Control System
TRANSMISSION
Automatic Transmission
Transmission Control System
Manual Transmission
Clutch
BODY AND ACCESSORIES
Lighting System
Wiper/Washer System
Entertainment
Wiring System
Meter and Gauge
Body Structure
Seats
Security and Locks
Sun Roof/Convertible Top
Exterior/Interior Trim
RESTRAINTS
Seat Belt System
Supplemental Restraint System (Air Bag System)
Restraint Control System
...
CONTROL SYSTEM
Cruise Control System
TOP....0
RIGHT HAND MODEL....2
1999 MODEL....2
(UE) FRONTERA....3
Sec.0 GENERAL INFORMATION....4
0A GENERAL INFORMATION....4
General Repair Instruction....4
Illustration Arrows....5
Identification....6
Lifting Instructions....8
Standard Bolts Torque Specifications....11
Abbreviations Charts....12
Service Parts Identification Plate....14
0B MAINTENANCE AND LUBRICATION....15
Maintenance Schedule List....15
Service and Maintenance....16
Recommended Fluids and Lubricants....23
Lubricant Viscosity Chart....24
Recommended Liquid Gasket....26
Recommended Thread Locking Agents....27
Maintenance Service Data....28
Sec.1 HEATING, VENTILATION AND AIR CONDITIONING....29
1A HVAC SYSTEMS....29
Service Precaution....31
Heating and Ventilation System....31
General Description....31
Heater and Ventilation Associated Parts....32
Ventilation....33
Circuit Diagram....36
Diagnosis....37
Individual Inspection....41
Heater Unit....43
Heater Unit and Associated Parts....43
Removal....43
Installation....44
Heater Core and / or Mode Door....44
Disassembled View....44
Removal....44
Inspection....45
Installation....45
Heater Mode Control Link Unit....46
Disassembled View....46
Removal....46
Installation....47
Heater Temperature Control Link Unit....47
Disassembled View....47
Removal....47
Installation....48
Blower Assembly....48
Blower Assembly and Associated Parts....48
Removal....48
Installation....49
Blower Link Unit and / or Mode door....49
Disassembled View....49
Removal....49
Installation....50
Blower Motor....51
Blower Motor and Associated Parts....51
Removal....51
Installation....51
Rear Heater Duct, Defroster Nozzle and Ventilation Duct....52
Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts....52
Removal....52
Installation....53
Control Lever Assembly and / or Control Cable....53
Control Lever Assembly, Control Cable and Associated Parts....53
Removal....54
Installation....55
Control Panel Illumination Bulb....56
Control Panel Illumination Bulb and Associated Parts....56
Removal....56
Installation....56
Resistor....56
Resistor and Associated Parts....56
Removal....56
Installation....56
Air Conditioning System....57
General Description....57
Circuit Diagram....64
Diagnosis....66
Individual Inspection....74
General Repair Procedure....75
Leak Check....76
Compressor Assembly....82
Compressor Assembly and Associated Parts (6VD1)....82
Removal....82
Installation....83
Compressor Assembly and Associated Parts (X22SE)....84
Removal....84
Installation....85
New Compressor Installation....85
Condenser Assembly....86
Condenser Assembly and Associated Parts....86
Removal....86
Installation....86
Condenser Fan Motor....87
Condenser Fan Motor and Associated Parts....87
Removal....87
Installation....87
Receiver / Drier....88
Receiver / Drier and Associated Parts....88
Removal....88
Installation....88
Pressure Switch....89
Pressure Switch and Associated Parts....89
Removal....89
Installation....89
Evaporator Assembly....90
Evaporator Assembly and Associated Parts....90
Removal....90
Installation....91
Electronic Thermostat, Evaporator Core and/or Expansion Valve....92
Disassembled View....92
Removal....92
Installation....93
Refrigerant Line....94
Refrigerant Line and Associated Parts....94
Removal....94
Installation....95
Main Data And Specifications....96
Compressor....99
Service Precaution....99
General Description....99
Diagnosis....100
Magnetic Clutch Assembly (DKV-14D Type)....101
Parts Location View....101
Removal....101
Inspection and Repair....103
Installation....103
Compressor Oil....105
Oil Specification....105
Handling of Oil....105
Compressor Oil Check....105
Checking and Adjusting Oil Quantity for Used Compressor....105
Checking and Adjusting for Compressor Replacement....106
Contamination of Compressor Oil....106
Oil Return Operation....106
Replacement of Component Parts....106
Main Data and Specifications....107
Special Tools....109
Automatic Air Conditioning System....110
General Description....110
Automatic Air Conditioner Parts Configuration....110
Refrigerant Line and Associated Parts....111
Circuit Diagram....112
Functions and Features....118
Automatic Air Conditioner Block Diagram....119
Control Panel Layout....120
Air Control Functions....121
Operation and Functions of Control Panel Switches....122
Overview of Construction, Movement and Control of Major Parts of Automatic Air Conditioner System....125
Overview of Automatic Control of Automatic Air Conditioner....128
Troubleshooting....132
Troubleshooting, Its Overview and Procedures....132
Auto Air Conditioner Control Unit Power Supply Diagnosis....133
Performance and Movement checklist for Automatic Air Conditioner Related Parts....135
Troubleshooting With Self-Diagnosis Function....137
Inspection By Failed Location....141
Inspection of the Sensors....141
Inspection of the Intake Actuator System....145
Inspection of the Mix Actuator System....148
Inspection of the Mode Actuator System....151
Inspection of the Fan Motor System....154
Inspection of the Magnetic Clutch System....158
Condenser Fan Diagnosis....161
Individual Inspection....164
On-Vehicle Service....168
Power Transistor....168
Removal....168
Installation....168
Automatic Heater/Air Conditioner Control Unit....168
Removal....168
Installation....168
Interior Temperature Sensor (Aspirator)....169
Removal....169
Installation....169
Outside Air Temperature Sensor....169
Removal....169
Installation....169
Solar Radiation Sensor....170
Removal....170
Installation....170
Electronic Thermostat....170
Removal....170
Installation....170
Mode Actuator....171
Removal....171
Installation....171
Mix Actuator....171
Removal....171
Installation....171
Intake Actuator....172
Removal....172
Installation....172
Sec.2 STEERING....173
2A POWER-ASSISTED STEERING SYSTEM....173
Service Precaution....174
Diagnosis....174
General Description....180
Power Steering System Test....182
Maintenance....183
Fluid Level....183
Bleeding The Power Steering System....183
Bleeding Procedure....183
Flushing The Power Steering System....184
Steering Wheel Free Play Inspection....184
Front End Alignment Inspection and Adjustment....184
Main Data and Specifications....188
Special Tools....189
Power Steering Unit....190
Power Steering Unit and Associated Parts....190
Removal....190
Installation....191
Power Steering Unit Disassembled View....192
Disassembly....192
Inspection and Repair....192
Reassembly....192
Main Data and Specifications....193
Special Tools....193
Power Steering Pump....194
Power Steering Pump and Associated Parts....194
Removal....194
Installation....194
Power Steering Pump Disassembled View....195
Disassembly....195
Inspection and Repair....196
Reassembly....196
Main Data and Specifications....198
Transfer Gear Assembly....199
Removal....199
Inspection and Repair....199
Installation....199
Supplemental Restraint System Steering Wheel & Column....200
Service Precaution....200
SRS Connectors....200
Inflator Module....202
Inflator Module and Associated Parts....202
Removal....202
Inspection and Repair....203
Installation....203
Steering Wheel....204
Steering Wheel and Associated Parts....204
Removal....204
Installation....206
Combination Switch....207
Combination Switch and Associated Parts....207
Removal....207
Installation....209
Lock Cylinder....211
Lock Cylinder and Associated Parts....211
Removal....211
Installation....213
System Inspection....214
Steering Column....215
Steering Column and Associated Parts....215
Removal....215
Insepction....218
Installation....219
System Inspection....220
Supplemental Restraint System Steering Wheel & Column and Associated Parts....221
Main Data and Specifications....221
Special Tools....221
Sec.3 SUSPENSION....222
3C FRONT SUSPENSION....222
Service Precaution....222
General Description....223
Diagnosis....223
Shock Absorber....226
Shock Absorber and Associated Parts....226
Removal....226
Inspection and Repair....226
Installation....226
Stabilizer Bar....227
Stabilizer Bar and Associated Parts....227
Removal....227
Inspection and Repair....227
Installation....227
Shock Absorber....226
Shock Absorber and Associated Parts....226
Removal....226
Inspection and Repair....226
Installation....226
Stabilizer Bar....227
Stabilizer Bar and Associated Parts....227
Removal....227
Inspection and Repair....227
Installation....227
Torsion Bar....228
Torsion Bar and Associated Parts....228
Removal....228
Inspection and Repair....229
Installation....229
Knuckle....231
Knuckle and Associated Parts....231
Removal....231
Inspection and Repair....232
Installation....232
Upper Control Arm....234
Upper Control Arm and Associated Parts....234
Removal....234
Inspection and Repair....235
Installation....235
Lower Control Arm....238
Lower Control Arm and Associated Parts....238
Removal....238
Inspection and Repair....239
Installation....240
Upper Ball Joint....242
Upper Ball Joint and Associated Parts....242
Removal....242
Inspection and Repair....243
Installation....243
Lower Ball Joint....244
Lower Ball Joint and Associated Parts....244
Removal....244
Inspection and Repair....245
Installation....245
Main Data and Specifications....246
Special Tools....247
3D REAR SUSPENSION....248
Service Precaution....248
General Description....248
Diagnosis....249
Coil Spring....252
Coil Spring and Associated Parts....252
Removal....252
Inspection and Repair....253
Installation....253
Shock Absorber....254
Removal....254
Inspection and Repair....254
Installation....254
Trailing Link....255
Trailing Link and Associated Parts....255
Removal....255
Inspection and Repair....255
Installation....256
Upper Link....257
Upper Link and Associated Parts....257
Removal....257
Inspection and Repair....257
Installation....258
Lateral Rod....259
Lateral Rod and Associated Parts....259
Removal....259
Inspection and Repair....259
Installation....260
Stabilizer Bar....261
Stabilizer Bar and Associated Parts....261
Removal....261
Inspection and Repair....261
Installation....262
Main Data and Specifications....263
Special Tools....265
3E WHEEL AND TIRE SYSTEM....266
Service Precaution....266
General Description....267
Diagnosis....268
Wheel....276
Wheel and Associated Parts....276
Removal....276
Installation....276
Tire....277
Tire Replacement....277
General Balance Procedure....277
Balancing Wheel and Tire....278
Main Data and Specifications....279
Sec.4 DRIVELINE/AXLE....280
4A1 DIFFERENTIAL (FRONT)....280
Service Precaution....280
Front Drive Axle....281
Diagnosis....281
Pinion Shaft Oil Seal....282
Pinion Shaft Oil Seal and Associated Parts....282
Removal....282
Inspection and Repair....283
Installation....283
Front Drive Axle Assembly....284
Front Drive Axle Assembly and Associated Parts....284
Removal....285
Installation....286
Differential Assembly....287
Disassembled View....287
Disassembly....288
Reassembly....290
Differential Cage Assembly....299
Disassembled View....299
Disassembly....299
Inspection and Repair....300
Reassembly....301
Main Data and Specifications....303
Special Tools....306
4A2 DIFFERENTIAL (REAR)....308
Service Precaution....308
General Description....309
Diagnosis....310
Axle Housing....312
Axle Housing and Associated Parts....312
Removal....312
Installation....314
Axle Shaft, Oil Seal and Bearing....314
Axle Shaft and Associated Parts....314
Removal....314
Inspection....315
Installation....315
Pinion Oil Seal....317
Pinion Oil Seal and Associated Parts....317
Removal....317
Inspection and Repair....318
Installation....318
Differential Assembly....320
Disassembled View....320
Inspecting the Axle Before Disassembly....321
Disassembly....321
Inspection and Repair....323
Reassembly....324
Side Bearing Preload Adjustment....328
Pinion Installation....329
Determination of Backlash & Preload Shims....330
Backlash Adjustment....331
Gear Tooth Pattern Check....332
Adjustments Affecting Tooth Contact....333
Differential Case Assembly....334
Disassembled View....334
Disassembly....335
Inspection and Repair....335
Reassembly....335
Limited Slip Differential Assembly....336
Disassembled View....336
Disassembly....336
Inspection and Repair....338
Reassembly....338
Main Data And Specifications....340
Special Tools....342
4B DRIVELINE CONTROL SYSTEM....344
Service Precaution....344
Shift On The Fly System....345
Outline of Shift on The Fly System....345
Functions of Indicator Lamp....349
Diagnosis....350
Shift On The Fly Vacuum Piping and Electrical Equipment....361
Vacuum Piping Diagram....361
Actuator Assembly....361
Vacuum Tank....361
Inspection and Repair....362
4WD Control Unit....365
4WD Control Unit Associated Parts....365
Removal....366
Installation....366
4C DRIVE SHAFT SYSTEM....367
Service Precaution....367
General Description....368
Diagnosis....368
Front Hub and Disc....369
Disassembled View....369
Disassembly....369
Inspection and Repair....370
Reassembly....371
Front Drive Shaft Joint....374
Front Drive Shaft Joints Replacement....374
Front Axle Drive Shaft....375
Front Axle Drive Shaft and Associated Parts....375
Disassembly....376
Inspection And Repair....377
Bushing Replacement....377
Reassembly....377
Shift On The Fly System....380
Shift On The Fly System and Associated Parts....380
Disassembly....380
Inspection And Repair....382
Reassembly....385
Main Data and Specifications....388
Special Tools....390
Propeller Shaft....391
General Description....391
Universal Joint....392
Diagnosis of Propeller Shaft and Universal Joint....393
Front Propeller Shaft....394
Front Propeller Shaft and Associated Parts....394
Removal....394
Installation....395
Slip Joint Disassembly....395
Universal Joint Disassembly (Single Cardan Type)....396
Universal Joint Disassembly (Double Cardan Type)....398
Inspection and Repair....399
Universal Joint Reassembly (Single Cardan Type)....401
Universal Joint Reassembly (Double Cardan Type)....402
Slip Joint Reassembly....404
Main Data and Specifications....405
Rear Propeller Shaft....406
Rear Propeller Shaft and Associated Parts....406
Removal....406
Installation....406
Slip Joint Disassembly....407
Universal Joint Disassembly....408
Inspection....410
Universal Joint Reassembly....411
Slip Joint Reassembly....412
Main Data and Specifications....413
4D TRANSFER CASE....414
Service Precaution....414
General Description....415
Transfer Rear Oil Seal....417
Transfer Rear Oil Seal and Associated Parts....417
Removal....417
Installation....417
Transfer Case Assembly (A/T)....419
Transfer Case Assembly (A/T) and Associated Parts....419
Removal....420
Installation....421
Transfer Rear Case Assembly (A/T)....424
Transfer Rear Case Assembly (A/T) and Associated Parts....424
Removal....424
Installation....426
Transfer Rear Cover Assembly....429
Disassembly....429
Inspection and Repair....430
Reassembly....430
Detent, Shift Arm, and Interlock Pin (Transfer Case Assembly)....432
Disassembled View....432
Disassembly....433
Inspection and Repair....434
Reassembly....434
Transfer Case Assembly....436
Disassembled View....436
Disassembly....437
Inspection and Repair....440
Reassembly....443
Main Data and Specifications....450
Special Tools....453
Sec.5 BRAKES....455
5A BRAKE CONTROL SYSTEM....455
Service Precaution....456
General Description....457
Functional Description....458
System Components....464
Electronic Hydraulic Control Unit (EHCU)....464
ABS Warning Light....464
Wheel Speed Sensor....464
G-Sensor....464
Normal and Anti-lock Braking....464
Brake Pedal Travel....464
Acronyms and Abbreviations....465
General Diagnosis....465
General Information....465
ABS Service Precautions....465
Computer System Service Precautions....465
General Service Precautions....465
Note on Intermittents....466
Test Driving ABS Complaint Vehicles....466
"ABS" Warning Light....466
Normal Operation....466
Tech 2 Scan Tool....467
DATA LIST....470
ACTUATOR TEST....471
Tech 2 Service Bleed....475
Basic Diagnostic Flow Chart....477
Basic Inspection Procedure....477
EHCU Connector Pin-out Checks....478
Circuit Diagram....479
Connector List....481
Part Location....483
Symptom Diagnosis....484
Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate....484
Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)....485
Chart A-2 Uneven Braking Occurs While ABS Works....485
Chart TA-2 Uneven Braking Occurs While ABS Works (Use TECH 2)....485
Chart A-3, TA-3 The Wheels Are Locked....486
Chart A-4 Brake Pedal Feed Is Abnormal....486
Chart A-5, TA-5 Braking Sound (From EHCU) Is Heard While Not Braking....487
Diagnostic Trouble Codes....488
Diagnosis By "ABS" Warning Light Illumination Pattern....490
Diagnostic Trouble Codes (DTCs)....491
Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated.....493
Chart B-2 CPU Error (DTC 14 (Flash out) / C0271, C0272, C0273, C0284 (Serial communications))....493
Chart B-3 Low or High Ignition Voltage (DTC 15 (Flash out) / C0277, 0278 (Serial communications))....494
Chart B-4 Excessive Dump Time (DTC 17 (Flash out) / C0269 (Serial communications))....494
Chart B-5 Excessive Isolation Time (DTC 18 (Flash out) / C0274 (Serial communications))....494
Chart B-6 G-Sensor Output Failure (DTC 21 (Flash out) / C0276 (Serial communications))....495
Chart B-7 Brake Switch Failure (DTC 22 (Flash out) / C0281 (Serial communications))....495
Chart B-8 2WD Controller in 4WD Vehicle Controller (DTC 13 (Flash out) / C0285 (Serial communications)), 4WD State Input....496
Chart B-9 Pump Motor Failure (DTC 32 (Flash out) / C0267, C0268 (Serial communications))....496
Chart B-10 EHCU Valve Relay Failure (DTC 35 (Flash out) / C0265, C0266 (Serial communications))....497
Chart B-11 FL Isolation Solenoid Coil Failure (DTC 41 (Flash out) / C0245, C0247 (Serial communications))....497
Chart B-12 FL Dump Solenoid Coil Failure (DTC 42 (Flash out) / C0246, C0248 (Serial communications))....497
Chart B-13 FR Isolation Solenoid Coil Failure (DTC 43 (Flash out) / C0241, C0243 (Serial communications))....498
Chart B-14 FR Dump Solenoid Coil Failure (DTC 44(Flash out) / C0242, C0244 (Serial communications))....498
Chart B-15 Rear Isolation Solenoid Coil Failure (DTC 45 (Flash out) / C0251, C0253 (Serial communications))....498
Chart B-16 Rear Dump Solenoid Coil Failure (DTC 46 (Flash out) / C0252, C0254 (Serial communications))....499
Chart B-17 FL Speed Sensor Open or Shorted (DTC 51 (Flash out) / C0225 (Serial communications))....499
Chart B-18 FR Speed Sensor Open or Shorted (DTC 52 (Flash out) / C0221 (Serial communications))....500
Chart B-19 Rear Speed Sensor Open or Shorted (DTC 53 (Flash out) / C0235 (Serial communications))....501
Chart B-20 FL Speed Sensor Missing (DTC 61 (Flash out) / C0226, C0227 (Serial communications))....502
Chart B-21 FR Speed Sensor Missing (DTC 62 (Flash out) / C0222, C0223 (Serial communications))....503
Chart B-22 Rear Speed Sensor Missing (DTC 63 (Flash out) / C0236, C0237 (Serial communications))....504
Chart B-23 Simultaneous Drop-out of Front Speed Sensor Signal (DTC 64 (Flash out) / C0229 (Serial communications))....505
Chart B-24 Wheel Speed Input Abnormality (DTC 65 (Flash out) / C0238 (Serial communications))....506
Unit Inspection Procedure....507
Chart C-1-1 FL Sensor Output Inspection Procedure....507
Chart C-1-2 FR Sensor Output Inspection Procedure....508
Chart C-1-3 Rear Sensor Output Inspection Procedure....509
Chart TC-1 Sensor Output Inspection Procedure....509
Special Tools....510
5B ANTI-LOCK BRAKE SYSTEM....511
Service Precaution....511
Electronic Hydraulic Control Unit....512
Electronic Hydraulic Control Unit and Associated Parts....512
Removal....512
Disassembled View....513
Disassembly....513
Reassembly....513
Installation....513
Front Wheel Speed Sensor....514
Front Wheel Speed Sensor and Associated Parts....514
Removal....514
Inspection and Repair....514
Installation....514
Rear Wheel Speed Sensor....515
Removal....515
Inspection and Repair....515
Installation....515
5C POWER-ASSISTED BRAKE SYSTEM....516
Service Precaution....517
General Description....517
Diagnosis....520
General Diagnosis....521
Hydraulic Brakes....524
Filling Master Cylinder Reservoir....524
Deterioration of Brake Fluid....524
Leakage of Brake Fluid....524
Bleeding Brake Hydraulic System....524
Flushing Brake Hydraulic System....525
Brake Pipes and Hoses....525
Brake Hose Inspection....525
Front Caliper Brake Hose....526
Front Caliper Brake Hose and Associated Parts....526
Removal....526
Installation....526
Rear Axle Brake Hose....527
Rear Axle Brake Hose and Associated Parts....527
Removal....527
Installation....527
Brake Pipe....528
Removal....528
Installation....528
P & B (Proportioning and Bypass) Valve....529
P & B (Proportioning and Bypass) Valve Sectional View....529
Removal....529
Installation....529
Main Data and Specifications....530
Brake Pedal....531
Checking Pedal Height....531
Checking Pedal Travel....531
Brake Pedal and Associated Parts....532
Removal....532
Installation....532
Stoplight Switch....533
Parts Location....533
Removal....533
Installation....533
Main Data and Specifications....534
Fluid Reservoir Tank....535
Fluid Reservoir Tank and Associated Parts....535
Removal....535
Installation....535
Master Cylinder Assembly....536
Master Cylinder Assembly and Associated Parts....536
Removal....536
Inspection and Repair....536
Installation....538
Main Data and Specifications....538
Special Tools....538
Vacuum Booster Assembly....539
Vacuum Booster Assembly and Associated Parts....539
Removal....539
Inspection and Repair....539
Installation....540
Exterior Components....542
Exterior Components and Associated Parts....542
Removal....542
Inspection and Repair....543
Installation....543
Vacuum Booster Overhaul....543
Vacuum Booster....543
Main Data and Specifications....544
Special Tools....545
Front Disc Brake Pads....546
Front Disc Brake Pads Inspection....546
Front Disc Brake Pads and Associated Parts....546
Removal....547
Installation....547
Front Disc Brake Rotor....549
Inspection....549
Replacing Brake Rotors....549
Refinishing Brake Rotors....549
Front Disc Brake Caliper Assembly....551
Front Disc Brake Caliper Assembly and Associated Parts....551
Removal....551
Installation....552
Front Disc Brake Caliper....554
Front Disc Brake Caliper Disassembled View....554
Disassembly....554
Inspection and Repair....555
Reassembly....555
Main Data and Specifications....557
Rear Disc Brake Pads....558
Brake Pads Inspection....558
Brake Pads and Associated Parts....558
Removal....559
Installation....559
Rear Disc Brake Rotor....561
Inspection....561
Replacing Brake Rotors....561
Refinishing Brake Rotors....561
Rear Drum (In Disc) Inside Diameter Check....562
Rear Disc Brake Caliper Assembly....563
Rear Disc Brake Caliper Assembly and Associated Parts....563
Removal....563
Installation....564
Rear Disc Brake Caliper....566
Rear Disc Brake Caliper Disassembled View....566
Disassembly....566
Inspection and Repair....567
Reassembly....567
Main Data and Specifications....569
5D PARKING BRAKE SYSTEM....570
Service Precaution....570
General Description....570
Operation....571
Parking Brake Lever and Front Cable....572
Parking Brake Lever Assembly and Associated Parts....572
Removal....572
Installation....572
Parking Brake Rear Cable....573
Parking Brake Rear Cable and Associated Parts....573
Removal....574
Installation....574
Inspection and Repair....575
Parking Brake Adjustment....575
Main Data and Specifications....576
Sec.6 ENGINE....577
X22SE 2.2L ENGINE....577
6A ENGINE MECHANICAL....577
Service Precaution....578
General Description....578
Engine Diagnosis....580
Cylinder Head Cover....593
Removal....593
Installation....594
Exhaust Manifold....595
Removal....595
Installation....595
Crankshaft Pulley....596
Removal....596
Installation....596
Intake Manifold....597
Removal....597
Installation....598
Cylinder Head Assembly....600
Removal....600
Installation....602
Timing Belt....608
Removal....608
Installation....609
Camshaft....612
Removal....612
Installation....613
Engine Assembly....615
Engine and Associated Parts....615
Removal....615
Installation....617
Cylinder Head....619
Cylinder Head and Associated Parts....619
Disassembly....619
Inspection and Repair....620
Reassembly....621
Valve Spring, Valve, Valve Guide....622
Valve Spring, Valve, Valve Guide and Associated Parts....622
Disassembly....623
Inspection and Repair....623
Reassembly....624
Camshaft....625
Camshaft and Associated Parts....625
Disassembly....625
Reassembly....626
Crankshaft....627
Crankshaft and Associated Parts....627
Disassembly....627
Inspection and Repair....628
Reassembly....630
Piston and Connecting Rod....633
Piston, Connecting Rod and Associate Parts....633
Disassembly....633
Inspection and Repair....634
Reassembly....636
Cylinder Block....637
Cylinder Block and Associated Parts....637
Disassembly....638
Inspection and Repair....638
Reassembly....639
Cylinder Head Cover....640
Cylinder Head Cover and Associated parts....640
Removal....641
Installation....641
Balance Unit Assembly....643
Balance Unit Assembly Associated Parts....643
Disassembly....644
Adjustment....644
Reassembly....646
Main Data and Specifications....648
Special Tools....653
6B ENGINE COOLING....655
Service Precaution....655
General Description....656
Diagnosis....658
Draining and Refilling Cooling System....658
Water Pump....659
Water Pump and Associated Parts....659
Removal....659
Inspection....659
Installation....659
Thermostat....660
Removal....660
Inspection....660
Installation....660
Radiator....661
Radiator and Associated Parts....661
Removal....661
Inspection....662
Installation....662
Main Data and Specifications....664
Special Tool....664
6C ENGINE FUEL....665
Service Precaution....665
General Description....666
Fuel Metering....667
Fuel Filter....668
Fuel Filter and Associated Parts....668
Removal....668
Inspection....668
Installation....668
Inspection....669
In-Tank Fuel Filter....669
Fuel Pump Flow Test....669
Fuel Pump....670
Fuel Pump and Associated Parts....670
Removal....670
Installation....671
Fuel Tube / Quick - Connector Fittings....672
Precautions....672
Cautions During Work....672
Removal....672
Reuse of Quick-Connector....673
Assembling Advice....673
Fuel Pump Relay....674
General Description....674
Fuel Tank....674
Fuel Tank and Associated Parts....674
Removal....675
Installation....675
Fuel Gage Unit....675
Removal and Installation....675
Fuel Filler Cap....676
General Description....676
Inspection....676
Main Data and Specifications....677
Special Tool....677
6D1 ENGINE ELECTRICAL....678
Service Precaution....678
Battery....679
General Description....679
Diagnosis....679
Battery Charging....680
Jump Starting....680
Battery Removal....681
Battery Installation....681
Main Data and Specifications....682
6D2 IGNITION SYSTEM....683
Service Precaution....683
General Description....683
Diagnosis....683
Ignition Module....684
Removal....684
Installation....684
Spark Plug....684
Removal....684
Inspection and Repair....684
Installation....685
Crankshaft Angle Sensor....686
Removal....686
Installation....686
Main Data and Specifications....687
6D3 STARTING AND CHARGING SYSTEM....688
Service Precaution....688
Starting System....689
General Description....689
Diagnosis....689
Starter....690
Removal....690
Installation....690
Disassembled View....691
Inspection and Repair....692
Characteristic Test....693
Charging System....694
General Description....694
General On-Vehicle Inspection....694
Generator....696
Removal....696
Inspection....696
Installation....697
Disassembly....697
Inspection and Repair....699
Reassembly....701
Main Data and Specifications....702
6E1 DRIVEABILITY AND EMISSIONS....703
SPECIFICATIONS....708
TIGHTENING SPECIFICATIONS....708
DIAGRAMS AND SCHEMATICS....709
ECM WIRING DIAGRAM (1 of 10)....709
ECM WIRING DIAGRAM (2 of 10)....710
ECM WIRING DIAGRAM (3 of 10)....711
ECM WIRING DIAGRAM (4 of 10)....712
ECM WIRING DIAGRAM (5 of 10)....713
ECM WIRING DIAGRAM (6 of 10)....714
ECM WIRING DIAGRAM (7 of 10)....715
ECM WIRING DIAGRAM (8 of 10)....716
ECM WIRING DIAGRAM (9 of 10)....717
ECM WIRING DIAGRAM (10 of 10)....718
ECM PINOUTS....719
ECM Pinout Table, 32‐Pin Red Connector-Row ”A”....719
ECM Pinout Table, 32‐Pin Red Connector-Row ”B”....720
ECM Pinout Table, 32‐Pin White Connector-Row ”C”....721
ECM Pinout Table, 32‐Pin White Connector-Row ”D”....722
ECM Pinout Table, 32‐Pin White Connector-Row ”E”....723
ECM Pinout Table, 32‐Pin White Connector-Row ”F”....724
COMPONENT LOCATOR....725
Undercarriage Component Locator Table....728
Fuse And Relay Panel (Underhood Electrical Center)....728
DIAGNOSIS Strategy‐Based Diagnostics....729
Strategy‐Based Diagnostics....729
DTC Stored....729
No DTC....729
No Matching Symptom....729
Intermittents....729
No Trouble Found....729
Verifying Vehicle Repair....729
GENERAL SERVICE INFORMATION....729
Non‐OEM Parts....729
Environment....730
Emissions Control Information Label....730
Maintenance Schedule....730
Visual/Physical Engine Compartment Inspection....730
Basic Knowledge Of Tools Required....730
SERIAL DATA COMMUNICATIONS....730
Class II Serial Data Communications....730
ON‐BOARD DIAGNOSTIC (OBD)....730
On‐Board Diagnostic Tests....730
Comprehensive Component Monitor Diagnostic Operation....731
Common OBD Terms....731
The Diagnostic Executive....732
DTC Types....733
Verifying Vehicle Repair....734
Reading Diagnostic Trouble Codes Using A Tech 2 Scan Tool....734
Tech 2 Features....736
Getting Started....736
Operating Procedure (Example)....737
DTC Modes....738
DTC Information Mode....738
Miscellaneous Test....739
Lamps Test....739
Relays Test....740
EVAP Test....742
Idle Air Control System Test....742
Fuel System Test....744
EGR Control Test....745
Injector Balance Test....745
Plotting Snapshot Graph....746
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)....747
Flow Chart for Snapshot Replay (Plotting Graph)....748
PRIMARY SYSTEM‐BASED DIAGNOSTICS....749
Primary System‐Based Diagnostics....749
Fuel Control Heated Oxygen Sensors....749
HO2S Heater....749
ON‐BOARD DIAGNOSTIC (OBD) SYSTEM CHECK....750
Circuit Description....750
Diagnostic Aids....750
Test Description....750
A/C CLUTCH CONTROL CIRCUIT DIAGNOSIS....752
Circuit Description....752
Diagnostic Aids....752
A/C Clutch Diagnosis....753
ELECTRONIC IGNITION SYSTEM DIAGNOSIS....755
VISUAL CHECK OF THE EVAPORATIVE EMISSION CANISTER....755
IDLE AIR CONTROL (IAC) VALVE....755
ENGINE CONTROL MODULE (ECM) DIAGNOSIS....755
MULTIPLE ECM INFORMATION SENSOR DTCs SET....756
Circuit Description....756
Diagnostic Aids....756
EXHAUST GAS RECIRCULATION (EGR) DIAGNOSIS....759
ENGINE Tech 2 DATA DEFINITIONS AND RANGES....759
TYPICAL SCAN DATA VALUES....761
Test Conditions....761
2.2L L‐4 Engine....761
NO MALFUNCTION INDICATOR LAMP (MIL)....764
Circuit Description....764
Diagnostic Aids....764
Test Description....764
MALFUNCTION INDICATOR LAMP (MIL) ON STEADY....767
Circuit Description....767
Diagnostic Aids....767
Test Description....767
ENGINE CRANKS BUT WILL NOT RUN....769
Circuit Description....771
Diagnostic Aids....771
FUEL SYSTEM ELECTRICAL TEST....775
Circuit Description....775
Diagnostic Aids....775
Test Description....775
Fuel Pressure Relief Procedure....776
Fuel Gauge Installation....776
FUEL SYSTEM DIAGNOSIS....778
Circuit Description....778
Test Description....778
Fuel Pressure Relief Procedure....779
Fuel Gauge Installation....779
IDLE AIR CONTROL (IAC) SYSTEM CHECK....783
Circuit Description....783
Diagnostic Aids....783
EXHAUST GAS RECIRCULATION (EGR) SYSTEM CHECK....785
Circuit Description....785
Diagnostic Aids....785
MANIFOLD ABSOLUTE PRESSURE (MAP) OUTPUT CHECK....787
Circuit Description....787
Test Description....787
ECM DIAGNOSTIC TROUBLE CODES....789
ECM Diagnostic Trouble Codes....789
DIAGNOSTIC TROUBLE CODE (DTC) P0106 MANIFOLD ABSOLUTE PRESSURE (MAP) CIRCUIT/RANGE PERFORMANCE PROBLEM....791
DIAGNOSTIC TROUBLE CODE (DTC) P0107 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT LOW INPUT....794
DIAGNOSTIC TROUBLE CODE (DTC) P0108 MANIFOLD ABSOLUTE PRESSURE (MAP) CIRCUIT HIGH INPUT....797
DIAGNOSTIC TROUBLE CODE (DTC) P0112 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT LOW INPUT....800
DIAGNOSTIC TROUBLE CODE (DTC) P0113 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT HIGH INPUT....803
DIAGNOSTIC TROUBLE CODE (DTC) P0117 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT LOW INPUT....806
DIAGNOSTIC TROUBLE CODE (DTC) P0118 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT HIGH INPUT....808
DIAGNOSTIC TROUBLE CODE (DTC) P0121 THROTTLE POSITION (TP) SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM....811
DIAGNOSTIC TROUBLE CODE (DTC) P0122 THROTTLE POSITION (TP) SENSOR CIRCUITLOW INPUT....814
DIAGNOSTIC TROUBLE CODE (DTC) P0123 THROTTLE POSITION (TP) SENSOR CIRCUIT HIGH INPUT....817
DIAGNOSTIC TROUBLE CODE (DTC) P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)....820
DIAGNOSTIC TROUBLE CODE (DTC) P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)....823
DIAGNOSTIC TROUBLE CODE (DTC) P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1)....826
DIAGNOSTIC TROUBLE CODE (DTC) P0135 O2 SENSOR HEATER CIRCUIT MALFUNCTION....829
DIAGNOSTIC TROUBLE CODE (DTC) P0171 SYSTEM TOO LEAN (BANK 1)....832
DIAGNOSTIC TROUBLE CODE (DTC) P0172 SYSTEM TOO RICH (BANK 1)....836
DIAGNOSTIC TROUBLE CODE (DTC) P0201 INJECTOR CIRCUIT MALFUNCTION-CYLINDER 1....840
DIAGNOSTIC TROUBLE CODE (DTC) P0202 INJECTOR CIRCUIT MALFUNCTION-CYLINDER 2....843
DIAGNOSTIC TROUBLE CODE (DTC) P0203 INJECTOR CIRCUIT MALFUNCTION- CYLINDER 3....846
DIAGNOSTIC TROUBLE CODE (DTC) P0204 INJECTOR CIRCUIT MALFUNCTION-CYLINDER 4....849
DIAGNOSTIC TROUBLE CODE (DTC) P0325 KNOCK SENSOR (KS) CIRCUIT MALFUNCTION....852
DIAGNOSTIC TROUBLE CODE (DTC) P0327 KNOCK SENSOR (KS) CIRCUIT LOW INPUT....855
DIAGNOSTIC TROUBLE CODE (DTC) P0336 CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT RANGE/PERFORMANCE....858
DIAGNOSTIC TROUBLE CODE (DTC) P0337 CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT LOW INPUT....860
DIAGNOSTIC TROUBLE CODE (DTC) P0341 CAMSHAFT POSITION (CMP) SENSOR CIRCUIT RANGE/PERFORMANCE....862
DIAGNOSTIC TROUBLE CODE (DTC) P0342 CAMSHAFT POSITION (CMP) SENSOR CIRCUIT LOW INPUT....865
DIAGNOSTIC TROUBLE CODE (DTC) P0351 IGNITION COIL ”A” PRIMARY/SECONDARY CIRCUIT MALFUNCTION....868
DIAGNOSTIC TROUBLE CODE (DTC) P0352 IGNITION COIL ”B” PRIMARY/SECONDARY CIRCUIT MALFUNCTION....870
DIAGNOSTIC TROUBLE CODE (DTC) P0401 EXHAUST GAS RECIRCULATION (EGR) FLOW INSUFFICIENT DETECTED....872
DIAGNOSTIC TROUBLE CODE (DTC) P0402 EXHAUST GAS RECIRCULATION (EGR) EXCESSIVE FLOW DETECTED....875
DIAGNOSTIC TROUBLE CODE (DTC) P0404 EXHAUST GAS RECIRCULATION (EGR) CIRCUIT RANGE/PERFORMANCE....877
DIAGNOSTIC TROUBLE CODE (DTC) P0405 EXHAUST GAS RECIRCULATION (EGR) SENSOR CIRCUIT LOW....881
DIAGNOSTIC TROUBLE CODE (DTC) P0406 EXHAUST GAS RECIRCULATION (EGR) SENSOR CIRCUIT HIGH....884
DIAGNOSTIC TROUBLE CODE (DTC) P0443 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT MALFUNCTION....887
DIAGNOSTIC TROUBLE CODE (DTC) P0480 COOLING FAN 1 CONTROL CIRCUIT MALFUNCTION....889
DIAGNOSTIC TROUBLE CODE (DTC) P0481 COOLING FAN 2 CONTROL CIRCUIT MALFUNCTION....892
DIAGNOSTIC TROUBLE CODE (DTC) P0502 VEHICLE SPEED SENSOR (VSS) CIRCUIT LOW INPUT....895
DIAGNOSTIC TROUBLE CODE (DTC) P0506 IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED....897
DIAGNOSTIC TROUBLE CODE (DTC) P0507 IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED....900
DIAGNOSTIC TROUBLE CODE (DTC) P0563 SYSTEM VOLTAGE HIGH....903
DIAGNOSTIC TROUBLE CODE (DTC) P0601 INTERNAL CONTROL MODULE MEMORY CHECK SUM ERROR....905
DIAGNOSTIC TROUBLE CODE (DTC) P1106 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE....906
DIAGNOSTIC TROUBLE CODE (DTC) P1107 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE....908
DIAGNOSTIC TROUBLE CODE (DTC) P1111 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE....910
DIAGNOSTIC TROUBLE CODE (DTC) P1112 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE....913
DIAGNOSTIC TROUBLE CODE (DTC) P1114 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE....915
DIAGNOSTIC TROUBLE CODE (DTC) P1115 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE....917
DIAGNOSTIC TROUBLE CODE (DTC) P1121 THROTTLE POSITION (TP) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE....920
DIAGNOSTIC TROUBLE CODE (DTC) P1122 THROTTLE POSITION (TP) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE....922
DIAGNOSTIC TROUBLE CODE (DTC) P1171 FUEL SYSTEM LEAN DURING ACCELERATION....924
DIAGNOSTIC TROUBLE CODE (DTC) 1404 EXHAUST GAS RECIRCULATION (EGR) CLOSED VALVE....927
DIAGNOSTIC TROUBLE CODE (DTC) P1625 ECM UNEXPECTED RESET....930
DIAGNOSTIC TROUBLE CODE (DTC) P1627 PCM A/D CONVERSION MALFUNCTION....932
DIAGNOSTIC TROUBLE CODE (DTC) P1635 5 VOLT REFERENCE VOLTAGE CIRCUIT MALFUNCTION....934
DIAGNOSTIC TROUBLE CODE (DTC) P1640 ODM OUTPUT CIRCUIT FAULT....936
SYMPTOM DIAGNOSIS....939
DEFAULT MATRIX TABLE....962
Camshaft Position (CMP) Sensor....965
Crankshaft Position (CKP) Sensor....966
EEPROM....968
Engine Coolant Temperature (ECT) Sensor....968
Heated Oxygen Sensor (HO2S)....969
Intake Air Temperature (IAT) Sensor....970
Manifold Absolute Pressure (MAP) Sensor....971
Malfunction Indicator Lamp (MIL)....971
Engine Control Module (ECM)....972
Throttle Position (TP) Sensor....974
Vehicle Speed Sensor (VSS)....975
Air Filter....976
Idle Air Control (IAC) Valve....977
Intake Air Duct....979
Knock Sensor....980
Oil Pressure Switch....981
FUEL METERING SYSTEM Ac-celerator Cable Assembly....982
Accelerator Pedal Replacement....984
Fuel Filler Cap....984
Fuel Filler Cap....984
Fuel Filter....984
Fuel Injectors....986
Fuel Pressure Regulator....987
Fuel Pump Assembly....989
Fuel Pump Relay....991
Fuel Rail Assembly....991
Fuel Tank....993
Throttle body (TB)....994
ELECTRONIC IGNITION SYSTEM Ignition Control Module (ICM)....996
Ignition Coil....997
Spark Plugs....997
Spark Plug Cables....999
Spark Plug Cables....999
EMISSIONS Catalytic Converter....999
Air Conditioning Relay....999
Ignition Timing Adjustment....1000
EVAP Canister Hoses....1000
EVAP Canister....1000
Linear Exhaust Gas Recirculation (EGR) Valve....1000
Wiring and Connectors....1001
ECM Connectors And Terminals....1001
Connectors And Terminals....1002
Wire Harness Repair: Twisted Shielded Cable....1002
Twisted Leads....1003
Weather-Pack Connector....1004
Com‐Pack III....1005
Metri‐Pack....1005
GENERAL DESCRIPTION -ECM AND SENSORS....1006
58X Reference ECM Input....1006
A/C Request Signal....1006
Crankshaft Position (CKP) Sensor....1006
Camshaft Position (CMP) Sensor And Signal....1006
Engine Coolant Temperature (ECT) Sensor....1007
Electrically Erasable Programmable Read Only Memory (EEPROM)....1007
Fuel Control Heated Oxygen Sensor (PreCatalyst)....1007
Intake Air Temperature (IAT) Sensor....1008
Linear Exhaust Gas Recirculation (EGR) Control....1008
Manifold Absolute Pressure (MAP) Sensor....1008
Engine Control Module (ECM)....1009
ECM Function....1009
ECM Components....1009
ECM Voltage Description....1009
ECM Inputs/Outputs....1009
ECM Service Precautions....1010
Throttle Position (TP) Sensor....1010
Transmission Range Switch....1010
Vehicle Speed Sensor (VSS)....1010
Use of Circuit Testing Tools....1010
Aftermarket Electrical And Vacuum Equipment....1011
Electrostatic Discharge Damage....1011
GENERAL DESCRIPTION-AIR INDUCTION....1011
Air Induction System....1011
GENERAL DESCRIPTION-FUEL METERING....1012
Acceleration Mode....1012
Accelerator Controls....1012
Battery Voltage Correction Mode....1012
CMP Signal....1012
Clear Flood Mode....1012
Deceleration Fuel Cutoff (DFCO) Mode....1012
Engine Speed/Vehicle Speed/ Fuel Disable Mode....1012
Fuel Cutoff Mode....1012
Fuel Injector....1012
Fuel Metering System Components....1012
Fuel Metering System Purpose....1013
Fuel Pressure Regulator....1013
Fuel Pump Electrical Circuit....1013
Fuel Rail....1013
Idle Air Control (IAC) Valve....1014
Run Mode....1014
Starting Mode....1014
Throttle Body Unit....1014
GENERAL DESCRIPTION-ELECTRONIC IGNITION SYSTEM....1015
Camshaft Position (CMP) Sensor....1015
Crankshaft Position (CKP) Sensor....1015
Electronic Ignition....1015
Ignition Coils....1015
Ignition Control....1015
Ignition Control Module (ICM)....1016
Ignition Control ECM Output....1016
Engine Control Module (ECM)....1016
Spark Plug....1017
A/C CLUTCH DIAGNOSIS....1018
A/C Clutch Circuit Operation....1018
A/C Clutch Circuit Purpose....1018
A/C Request Signal....1018
GENERAL DESCRIPTION-EVAPORATIVE EMISSION (EVAP) SYSTEM....1018
EVAP Emission Control System Purpose....1018
EVAP Emission Control System Operation....1019
GENERAL DESCRIPTION-EXHAUST GAS RECIRCULATION (EGR) SYSTEM....1019
EGR Purpose....1019
Linear EGR Valve....1019
Linear EGR Control....1019
Linear EGR Valve Operation And Results Of Incorrect Operation....1019
EGR Pintle Position Sensor....1019
GENERAL DESCRIPTION-POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM....1020
Crankcase Ventilation System Purpose....1020
SPECIAL TOOLS....1021
6F ENGINE EXHAUST....1022
Service Precaution....1022
General Description....1023
Front Exhaust Pipe....1024
Front Exhaust Pipe and Associated Parts....1024
Removal....1024
Installation....1024
Exhaust Silencer....1025
Exhaust Silencer and Associated Parts....1025
Removal....1025
Installation....1025
Rear Exhaust pipe....1026
Rear Exhaust pipe and Associated Parts....1026
Removal....1026
Installation....1026
Main Data and Specifications....1027
6G ENGINE LUBRICATION....1028
Service Precaution....1028
General Description....1029
Oil Pump....1030
Oil Pump and Associated Parts....1030
Disassembly....1031
Inspection and Repair....1031
Reassembly....1031
6H ENGINE SPEED CONTROL SYSTEM....1032
Service Precaution....1032
Accelerator Pedal Control Cable....1033
Removal....1033
Inspection....1033
Installation....1033
Adjustment....1033
Accelerator Pedal....1034
Accelerator Pedal and Associated Parts....1034
Removal....1034
Installation....1034
Adjustment....1034
6J INDUCTION....1035
Service Precaution....1035
Air Cleaner Filter....1036
Removal....1036
Inspection....1036
Installation....1036
6VD1 3.2L ENGINE....1037
6A ENGINE MECHANICAL....1037
Service Precaution....1038
General Description....1039
Engine Diagnosis....1040
Cylinder Head Cover LH....1055
Removal....1055
Installation....1056
Cylinder Head Cover RH....1058
Removal....1058
Installation....1059
Common Chamber....1061
Removal....1061
Installation....1061
Exhaust Manifold LH....1063
Removal....1063
Installation....1063
Exhaust Manifold RH....1064
Removal....1064
Installation....1064
Crankshaft Pulley....1065
Removal....1065
Installation....1065
Timing Belt....1066
Removal....1066
Installation....1067
Camshaft....1070
Removal....1070
Installation....1070
Cylinder Head....1073
Removal....1073
Installation....1073
Valve Stem Oil Controller , Valve Spring and Valve Guide....1074
Removal....1074
Installation....1074
Piston, Piston Ring and Connecting Rod....1075
Removal....1075
Installation....1076
Crankshaft and Main Bearings....1077
Removal....1077
Installation....1078
Rear Oil Seal....1082
Removal....1082
Installation....1082
Engine Assembly....1083
Removal....1083
Installation....1083
Cylinder Head....1086
Cylinder Head and Associated Parts....1086
Disassembly....1086
Clean....1087
Inspection and Repair....1087
Reassembly....1087
Valve Spring, Oil Controller, Valve, Valve Guide....1090
Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts....1090
Disassembly....1090
Inspection and Repair....1091
Reassembly....1094
Valve Clearance Adjustments....1095
Camshaft....1097
Camshaft and Associated Parts....1097
Disassembly....1097
Inspection and Repair....1098
Reassembly....1100
Crankshaft....1103
Crankshaft and Associated Parts....1103
Disassembly....1103
Inspection and Repair....1104
Inspection and Repair....1105
Reassembly....1107
Piston and Connecting Rod....1111
Piston, Connecting Rod and Associate Parts....1111
Disassembly....1111
Inspection and Repair....1112
Reassembly....1116
Cylinder Block....1119
Cylinder Block and Associated Parts....1119
Disassembly....1119
Inspection and Repair....1120
Reassembly....1121
Main Data and Specification....1124
Special Tool....1130
6B ENGINE COOLING....1132
Service Precaution....1132
General Description....1133
Diagnosis....1136
Draining and Refilling Cooling System....1137
Engine coolant change....1137
Water Pump....1138
Water Pump and Associated Parts....1138
Removal....1138
Inspection....1138
Installation....1138
Thermostat....1139
Thermostat and Associated Parts....1139
Removal....1139
Inspection....1139
Installation....1139
Radiator....1140
Radiator and Associated Parts....1140
Removal....1140
Inspection....1141
Installation....1142
Drive Belt and Cooling Fan....1143
Drive Belt and Associated Parts....1143
Inspection....1143
Installation....1143
Main Data and Specifications....1144
Special Tool....1145
6C ENGINE FUEL....1146
Service Precaution....1146
General Description....1147
Fuel Metering....1148
Fuel Filter....1149
Removal....1149
Inspection....1149
Installation....1149
Inspection....1149
In‐Tank Fuel Filter....1149
Fuel Pump Flow Test....1150
Fuel Pump....1151
Fuel Pump and Associated Parts....1151
Removal....1151
Installation....1151
Fuel Tube / Quick-Connector Fittings....1152
Precautions....1152
Cautions During Work....1152
Removal....1152
Reuse of Quick‐Connector....1153
Assembling Advice....1154
Fuel Pump Relay....1154
General Description....1154
Fuel Tank....1155
Fuel Tank and Associated Parts....1155
Removal....1155
Installation....1156
Installation....1156
Fuel Gauge Unit....1156
Removal and Installation....1156
Fuel Filler Cap....1156
General Description....1156
Inspection....1156
Main Data and Specifications....1157
6D1 ENGINE ELECTRICAL....1158
Service Precaution....1158
Battery....1159
General Description....1159
Diagnosis....1159
Battery Charging....1160
Jump Starting....1160
Battery Removal....1161
Battery Installation....1161
Main Data and Specifications....1162
6D2 IGNITION SYSTEM....1163
Service Precaution....1163
General Description....1164
Diagnosis....1164
Ignition Coil....1165
Removal....1165
Inspection and Repair....1165
Installation....1165
Spark Plug....1166
Removal....1166
Inspection and Repair....1166
Installation....1166
Crankshaft Position Sensor....1167
Removal....1167
Installation....1167
Main Data and Specifications....1168
6D3 STARTING AND CHARGING SYSTEM....1169
Service Precaution....1169
Starting System....1170
General Description....1170
Diagnosis....1172
Starter....1173
Removal....1173
Installation....1173
Disassembled View....1174
Disassembly....1175
Inspection and Repair....1177
Reassembly....1181
Main Data and Specifications....1183
Charging System....1186
General Description....1186
General On–Vehicle Inspection....1186
Generator....1187
Removal....1187
Inspection....1187
Installation....1188
Disassembled View....1188
Disassembly....1189
Inspection and Repair....1190
Reassembly....1192
Bench Test....1193
Main Data and Specifications....1194
6E2 DRIVEABILITY AND EMISSIONS....1195
Specification....1199
Tightening Specifications....1199
Diagrams and Schematics....1200
PCM Wiring Diagram (1 of 8)....1200
PCM Wiring Diagram (2 of 8)....1201
PCM Wiring Diagram (3 of 8)....1202
PCM Wiring Diagram (4 of 8)....1203
PCM Wiring Diagram (5 of 8)....1204
PCM Wiring Diagram (6 of 8)....1205
PCM Wiring Diagram (7 of 8)....1206
PCM Wiring Diagram (8 of 8)....1207
PCM Pinouts....1208
PCM Pinout Table, 32-Way Red Connector-Row “A”....1208
PCM Pinout Table, 32-Way Red Connector-Row “B”....1209
PCM Pinout Table, 32-Way White Connector-Row “C”....1210
PCM Pinout Table, 32-Way White Connector-Row “D”....1211
PCM Pinout Table, 32-Way Blue Connector-Row “E”....1212
PCM Pinout Table, 32-Way Blue Connector-Row “F”....1213
Component Locators....1214
Engine Component Locator Table....1214
Undercarriage Component Locator....1215
Undercarriage Component Locator Table....1215
Sensors and Miscellaneous Component Locators....1216
Fuse and Relay Panel (Underhood Electrical Center)....1218
Diagnosis....1219
Strategy-Based Diagnostics....1219
Strategy-Based Diagnostics....1219
DTC Stored....1219
No DTC....1219
No Matching Symptom....1219
Intermittents....1219
No Trouble Found....1219
Verifying Vehicle Repair....1219
General Service Information....1219
Non-OEM Parts....1219
Environment....1220
Emissions Control Information Label....1220
Maitenance Schedule....1220
Visual/Physical Engine Compartment Inspection....1220
Basic Knowledge of Tools Required....1220
Seral Data Communications....1220
Class II Serial Data Communications....1220
On-Board Diagnostic (OBD)....1220
On-Board Diagnostic Tests....1220
Comprehensive Component Monitor Diagnostic Operation....1221
Common OBD Terms....1221
The Diagnostic Executive....1222
DTC Types....1223
Verifying Vehicle Repair....1224
Reading Diagnostic Trouble Codes Using the TECH 2 Scan Tool....1224
Tech 2....1225
Tech 2 Features....1225
Getting Started....1226
Operating Procedure (For Example)....1226
DTC Modes....1227
DTC Information Mode....1228
Miscellaneous Test....1228
Lamps Test....1229
Relays Test....1229
EVAP Test....1231
Idle Air Control System Test....1231
Fuel System Test....1233
EGR Control Test....1234
Variable Intake Manifold Solenoid Test....1235
Injector Balance Test....1235
Plotting Snapshot Graph....1236
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)....1237
Flow Chart for Snapshot Replay (Plotting Graph)....1238
Primary System-Based Diagnostics....1239
Primary System-Based Diagnostics....1239
Fuel Control Heated Oxygen Sensors....1239
HO2S Heater....1239
On-Board Diagnostic (OBD) System Check....1240
Circuit Description....1240
Diagnostic Aids....1240
A/C Clutch Control Circuit Diagnosis....1242
Circuit Description....1243
Diagnostic Aids....1243
A/C Clutch Diagnosis....1243
Electronic Ignition System Diagnosis....1248
Visual Check of The Evaporative Emission Canister....1248
Fuel Metering System Check....1248
Idle Air Control (IAC) Valve....1248
Knock Sensor Diagnosis....1248
Powertrain Control Module (PCM) Diagnosis....1248
Multiple PCM Information Sensor DTCS Set....1248
Exhaust Gas Recirculation (EGR) Diagnosis....1252
Engine Tech 2 Data Definitions and Ranges....1252
Typical Scan Data Values....1254
No Malfunction Indicator Lamp (MIL)....1259
Malfunction Indicator Lamp (MIL) “ON” Steady....1262
Engine Cranks But Will Not Run....1265
Fuel System Diagnosis....1273
Idle Air Control (IAC) System Check....1278
Knock Sensor (KS) System Check (Engine Knock, Poor Performance, or Poor Economy)....1280
Exhaust Gas Recirculation (EGR) System Check....1282
Manifold Absolute Pressure (MAP) Output Check....1284
Evaporative (EVAP) Emissions Canister Purge Valve Check....1286
PCM Diagnostic Trouble Codes....1289
Diagnostic Trouble Code (DTC) P0101 MAF System Performance....1292
Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency....1295
Diagnostic Trouble Code (DTC) P0103 MAF Sensor Circuit High Frequency....1298
Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage....1300
Diagnostic Trouble Code (DTC) P0108 MAP Sensor Circuit Hight Voltage....1303
Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage....1306
Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage....1309
Diagnostic Trouble Code (DTC) P0117 ECT Sensor Circuit Low Voltage....1313
Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage....1315
Diagnostic Trouble Code (DTC) P0121 TP System Performance....1318
Diagnostic Trouble Code (DTC) P0122 TP Sensor Circuit Low Voltage....1321
Diagnostic Trouble Code (DTC) P0123 TP Sensor Circuit High Voltage....1324
Diagnostic Trouble Code (DTC) P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1....1327
Diagnostic Trouble Code (DTC) P0132 HO2S Circuit High Voltage Bank 1 Sensor 1....1330
Diagnostic Trouble Code (DTC) P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1....1333
Diagnostic Trouble Code (DTC) P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1....1336
Diagnostic Trouble Code (DTC) P0152 HO2S Circuit High Voltage Bank 2 Sensor 1....1339
Diagnostic Trouble Code (DTC) P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1....1342
Diagnostic Trouble Code (DTC) P0171 Fuel Trim System Too Lean Bank 1....1345
Diagnostic Trouble Code (DTC) P0172 Fuel Trim System Rich Bank 1....1349
Diagnostic Trouble Code (DTC) P0174 Fuel Trim System Lean Bank 2....1353
Diagnostic Trouble Code (DTC) P0175 Fuel Trim System Rich Bank 2....1357
Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit....1361
Diagnostic Trouble Code (DTC) P0202 Injector 2 Control Circuit....1364
Diagnostic Trouble Code (DTC) P0203 Injector 3 Control Circuit....1367
Diagnostic Trouble Code (DTC) P0204 Injector 4 Control Circuit....1370
Diagnostic Trouble Code (DTC) P0205 Injector 5 Control Circuit....1373
Diagnostic Trouble Code (DTC) P0206 Injector 6 Control Circuit....1376
Diagnostic Trouble Code (DTC) P0325 KS Module Circuit....1379
Diagnostic Trouble Code (DTC) P0327 KS Sensor Circuit....1381
Diagnostic Trouble Code (DTC) P0336 58X Reference Signal Circuit....1384
Diagnostic Trouble Code (DTC) P0337 CKP Sensor Circuit Low Frequency....1386
Diagnostic Trouble Code (DTC) P0341 CMP Sensor Circuit Performamce....1389
Diagnostic Trouble Code (DTC) P0342 CMP Sensor Circuit Low....1392
Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit....1396
Diagnostic Trouble Code (DTC) P0352 Ignition 2 Control Circuit....1399
Diagnostic Trouble Code (DTC) P0353 Ignition 3 Control Circuit....1402
Diagnostic Trouble Code (DTC) P0354 Ignition 4 Control Circuit....1405
Diagnostic Trouble Code (DTC) P0355 Ignition 5 Control Circuit....1408
Diagnostic Trouble Code (DTC) P0356 Ignition 6 Control Circuit....1411
Diagnostic Trouble Code (DTC) P0404 EGR Open Stuck....1414
Diagnostic Trouble Code (DTC) P0405 EGR Low Voltage....1416
Diagnostic Trouble Code (DTC) P0406 EGR High Voltage....1419
Diagnostic Trouble Code (DTC) P0502 VSS Circuit Low Input....1422
Diagnositc Troule Code (DTC) P0562 System Voltage Low....1425
Diagnostic Trouble Code (DTC) P0563 System Voltage High....1427
Diagnostic Trouble Code (DTC) P0601 PCM Memory....1428
Diagnostic Trouble Code (DTC) P1171 Fuel System Lean Dueing Acceleration....1429
Diagnostic Trouble Code (DTC) P1380 ABS Rough Road ABS System Fault....1432
Diagnostic Trouble Code (DTC) P1381 ABS Rough Road Class 2 Serial Link....1433
Diagnostic Trouble Code (DTC) P1404 EGR Stuck Closed....1434
Diagnostic Trouble Code (DTC) P1508 IAC System Low RPM....1436
Diagnostic Trouble Code (DTC) P1509 IAC System High RPM....1439
Diagnostic Trouble Code (DTC) P1625 PCM Unexpected Reset....1442
Diagnostic Trouble Code (DTC) P1640 Output Driver Module (ODM) “A” Fault....1443
Symptom Diagnosis....1445
Default Matrix Table....1470
On-Vehicle Service Camshaft Position (CMP) Sensor....1473
Crankshaft Position (CKP) Sensor....1474
Engine Coolant Temperature (ECT) Sensor....1474
Heated Oxygen Sensor (HO2S)....1475
Intake Air Temperature (IAT) Sensor....1477
Knock Sensor (KS)....1478
Mass Air Flow (MAF) Sensor....1479
Manifold Absolute Pressure (MAP) Sensor....1479
Malfunction Indicator Lamp (MIL)....1480
Powertrain Control Module (PCM)....1480
EEPROM....1482
Throttle Position (TP) Sensor....1482
Vehicle Speed Sensor (VSS)....1482
Air Cleaner/Air Filter....1484
Idle Air Control (IAC) Valve....1485
Common Chamber....1486
Accelerator Cable Assembly....1486
Accelerator Pedal Replacement....1489
Fuel Fillter Cap....1491
Fuel Filter....1491
Fuel Gauge Unit....1494
Fuel Injectors....1494
Fuel Pressure Regulator....1495
Fuel Metering System....1497
Fuel Pump Assembly....1497
Fuel Pump Relay....1498
Fuel Rail Assembly....1498
Fuel Tank....1499
Throttle Body (TB)....1499
Electronic Ignition System....1501
Catalytic Converter....1502
Air Conditioning Relay....1502
EVAP Canister Hoses....1502
EVAP Canister....1502
EVAP Canister Purge Solenoid....1504
Fuel Tank Vent Valve....1505
Linear Exhaust Gas Recirculation (EGR) Valve....1505
Positive Crankcase Ventilation (PCV) Valve....1506
Wiring and Connectors....1507
PCM Connectors and Terminals....1507
Wire Harness Repair: Twisted Shielded Cable....1507
Twisted Leads....1508
Weather-Pack Connector....1509
Com-Pack III....1511
Metri-Pack....1511
General Description (PCM and Sensors)....1512
58X Reference PCM Input....1512
A/C Request Signal....1512
Crankshaft Position (CKP) Sensor....1512
Camshaft Position (CMP) Sensor and Signal....1512
Engine Coolant Temperature (ECT) Sensor....1512
Electrically Erasable Programmable Read Only Memory (EEPROM)....1512
Fuel Control Heated Oxygen Sensors....1512
Intake Air Temperature (IAT) Sensor....1513
Knock Sensor....1513
Linear Exhaust Gas Recirculation (EGR) Control....1514
Mass Air Flow (MAF) Sensor....1514
Manifold Absolute Pressure (MAP) Sensor....1514
Powertrain Control Module (PCM)....1515
PCM Function....1515
PCM Components....1515
PCM Voltage Description....1515
PCM Input/Outputs....1515
PCM Service Precautions....1516
Throttle Position (TP) Sensor....1516
Transmission Fluid Temperature (TFT) Sensor....1516
Transmission Range Switch....1516
Vehicle Speed Sensor (VSS)....1516
Use of Circuit Testing Tools....1517
Aftermarket Electrical and Vacuum Equipment....1517
Electrostatic Discharge Damage....1517
Upshift Lamp....1517
General Description (Air Induction)....1517
Air Induction System....1517
General Description (Fuel Metering) ....1518
Acceleration Mode....1518
Accelerator Controls....1518
Battery Voltage Correction Mode....1518
CMP Signal....1518
Clear Flood Mode....1518
Deceleration Mode....1518
Engine Speed/Vehicle Speed/Fuel Disable Mode....1518
Fuel Cutoff Mode....1518
Fuel Injector....1518
Fuel Metering System Components....1518
Fuel Metering System Purpose....1519
Fuel Pressure Regulator....1519
Fuel Pump Electrical Circuit....1519
Fuel Rail....1519
Idle Air Control (IAC) Valve....1520
Run Mode....1520
Starting Mode....1520
Throttle Body Unit....1520
General Description (Electronic Ignition System)....1521
Camshaft Position (CMP) Sensor....1521
Crankshaft Position (CKP) Sensor....1521
Electronic Ignition....1521
Ignition Coils....1521
Ignition Control....1521
Ignition Control PCM Output....1522
Knock Sensor (KS) PCM Input....1523
Powertrain Control Module (PCM)....1523
Spark Plug....1523
A/C Clutch Diagnosis....1525
A/C Clutch Circuit Operation....1525
A/C Clutch Circuit Purpose....1525
A/C Request Signal....1525
General Description (Evaporative (EVAP) Emission System)....1525
EVAP Emission Control System Purpose....1525
EVAP Emission Control System Operation....1525
General Description (Exhaust Gas Recirculation (EGR) System)....1525
EGR Purpose....1525
Linear EGR Valve....1526
Linear EGR Control....1526
Linear EGR Valve Operation and Results of Incorrect Operation....1526
EGR Pintle Position Sensor....1526
General Description (Positive Crankcase Ventilation (PCV) System)....1526
Crankcase Ventilation System Purpose....1526
Crankcase Ventilation System Operation....1527
Special Tools....1528
6F ENGINE EXHAUST....1529
Service Precaution....1529
General Description....1530
Three Way Catalytic Converter RH and Forked Exhaust Pipe....1531
Three Way Catalytic Converter RH and Forked Exhaust Pipe and Associated Parts....1531
Removal....1531
Installation....1531
Three Way Catalytic Converter LH and Forked Exhaust Pipe....1532
Three Way Catalytic Converter LH and Forked Exhaust Pipe and Associated Parts....1532
Removal....1532
Installation....1532
Forked Exhaust Pipe....1533
Forked Exhaust Pipe and Associated Parts....1533
Removal....1533
Installation....1533
Exhaust Silencer....1534
Exhaust Silencer and Associated Parts....1534
Removal....1534
Installation....1534
Rear Exhaust pipe....1535
Rear Exhaust pipe and Associated Parts....1535
Removal....1535
Installation....1535
Main Data and Specifications....1536
6G ENGINE LUBRICATION....1537
Service Precaution....1537
General Description....1538
Oil Pump....1539
Oil Pump and Associated Parts....1539
Oil Pump and Associated Parts....1540
Inspection and Repair....1540
Reassembly....1541
Oil Pan and Crankcase....1543
Removal....1543
Installation....1543
Oil Pump....1546
Removal....1546
Installation....1546
Oil Pump Oil Seal....1548
Removal....1548
Installation....1548
Oil Filter....1549
Removal....1549
Installation....1549
Main Data and Specification....1550
Special Tool....1551
6H ENGINE SPEED CONTROL SYSTEM....1552
Service Precaution....1552
Accelerator Pedal Control Cable....1553
Removal....1553
Inspection....1553
Installation....1553
Accelerator Pedal....1554
Accelerator Pedal and Associated Parts....1554
Removal....1554
Installation....1554
6J INDUCTION....1555
Service Precaution....1555
Air Cleaner Element....1556
Removal....1556
Inspection....1556
Installation....1556
Sec.7 TRANSMISSION....1557
7A AUTOMATIC TRANSMISSION....1557
Service Precaution....1558
Construction....1559
Range Reference Chart....1560
Normal Operation of 1999 4L30‐E Transmission....1561
Diagnosis....1561
Driver Information....1561
General Diagnosis Procedure....1564
Preliminary Inspection Chart....1565
Checking Transmission Fluid Level and Condition....1566
Test Driving....1567
Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart....1568
Mechanical / Hydraulic Diagnosis Symptoms Index....1569
Stall Test....1578
Line Pressure Test....1579
Shift Speed Chart....1580
Lockup Speed Chart....1581
Changing Transmission Fluid....1582
Selector Lever....1582
Inspection....1582
Removal....1583
Installation....1584
Select Cable....1584
Removal....1584
Installation....1586
Shift Lock Cable....1588
Removal....1588
Installation....1589
Mode Switch....1590
Removal....1590
Installation....1590
Transmission....1592
Transmission and Associated Parts....1592
Removal....1593
Installation....1595
Solenoid (Main Case Valve Body)....1599
Removal....1599
Installation....1599
Solenoid (Adapter Case Valve Body)....1600
Removal....1600
Installation....1600
Valve Body Assembly (Main Case)....1601
Removal....1601
Installation....1601
Valve Body Assembly (Adapter Case)....1602
Removal....1602
Installation....1602
Powertrain Control Module (PCM)....1603
Removal....1603
Installation....1603
Speed Sensor (Extension Housing)....1604
Removal....1604
Installation....1604
Transmission Oil Temperature Sensor (Adapter Case)....1604
Removal....1604
Installation....1604
Front Oil Seal (Converter Housing)....1605
Removal....1605
Installation....1605
Rear Oil Seal (Extension Housing)....1605
Removal....1605
Installation....1605
Transmission (4L30‐E)....1606
Disassembly....1606
Reassembly....1610
Converter Housing and Oil Pump Assembly....1620
Disassembled View....1620
Disassembly....1620
Inspection and Repair....1620
Reassembly....1620
Oil Pump....1621
Disassembled View....1621
Disassembly....1621
Inspection and Repair....1621
Reassembly....1621
Main Case Valve Body....1622
Disassembled View....1622
Disassembly....1623
Inspection and Repair....1623
Reassembly....1623
Adapter Case Valve Body....1624
Disassembled View....1624
Disassembly....1624
Inspection and Repair....1624
Reassembly....1624
Third Clutch and Sprag Unit....1625
Disassembled View....1625
Disassembly....1625
Inspection and Repair....1626
Reassembly....1626
Third Clutch....1626
Disassembled View....1626
Disassemble....1627
Inspection and Repair....1627
Reassembly....1627
Sprag Unit....1628
Disassembled View....1628
Disassembly....1628
Inspection and Repair....1628
Reassembly....1628
Second Clutch....1629
Disassembled View....1629
Disassembly....1629
Inspection and Repair....1630
Reassembly....1630
3‐4 Accumulator Piston....1631
Disassembled View....1631
Disassembly....1631
Inspection and Repair....1631
Reassembly....1632
Reverse Clutch Piston and Center Support....1633
Disassembled View....1633
Disassembly....1634
Inspection and Repair....1634
Reassembly....1634
Overrun Clutch and Turbine Shaft....1635
Disassembled View....1635
Disassembly....1636
Inspection and Repair....1636
Reassembly....1636
Main Data and Specification....1638
Special Tools....1642
4L30–E Parts List....1645
7A1 TRANSMISSION CONTROL SYSTEM....1653
Service Precaution....1654
General Description....1654
Electronic Control Diagram....1655
Powertrain Control Module (PCM)....1656
Control System Diagram....1657
Shift Control....1658
Band Apply Control....1658
Torque Converter Clutch Control....1658
Line Pressure Control....1658
On‐Board Diagnostic System....1658
Fail Safe Mechanism....1658
Torque Management Control....1658
ATF Warning Control....1658
Shift Mode Control....1659
Gear Shift Control....1660
Winter Drive Mode....1661
Backup Mode....1661
Functions of Input / Output Components....1662
Diagnosis....1663
Electronic Diagnosis....1663
Check Trans Indicator....1663
Diagnostic Check....1663
“Check Trans” Check....1664
Tech 2 OBD II Connection....1665
F0: Transmission Data....1669
F1: PC Solenoid Data....1670
Flashing Code....1671
OBD II Diagnostic Management System....1672
16-Terminal Data Link Connector (DLC)....1673
Malfunction Indicator Lamp (MIL)....1674
Types Of Diagnostic Trouble Codes (DTCs)....1674
Clear DTC....1674
DTC Check....1675
PCM Precaution....1675
Information On PCM....1675
Intermittent Conditions....1676
Transmission and PCM Identification....1677
Isuzu Frontera....1677
Diagnostic Trouble Code (DTC) Identification....1678
DTC P0218/Flashing Code 71 Transmission Fluid Over Temperature....1679
DTC P0560/Flashing Code 72 System Voltage Malfunction....1681
DTC P0705/Flashing Code 73 Transmission Range Switch (Mode Switch) Illegal Position....1684
DTC P0706/Flashing Code 74 Transmission Range Switch (Mode Switch) Performance....1687
DTC P0712/Flashing Code 75 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input....1690
DTC P0713/Flashing Code 76 Transmission Fluid Temperature (TFT) Sensor Circuit High Input....1693
DTC P0719/Flashing Code 77 TCC Brake Switch Circuit High (Stuck On)....1696
DTC P0722/Flashing Code 78 Transmission Output Speed Sensor (OSS) Low Input....1699
DTC P0723/Flashing Code 79 Transmission Output Speed Sensor (OSS) Intermittent....1702
DTC P0730/Flashing Code 81 Transmission Incorrect Gear Ratio....1705
DTC P0748/Flashing Code 82 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical....1708
DTC P0753/Flashing Code 83 Shift Solenoid A Electrical....1710
DTC P0758/Flashing Code 84 Shift Solenoid B Electrical....1713
DTC P1790/Flashing Code 85 ROM Transmission Side Bad Check Sum....1717
DTC P1792/Flashing Code 86 EEPROM Transmission Side Bad Check Sum....1718
DTC P1835/Flashing Code 87 Kickdown Switch Always On....1719
DTC P1850/Flashing Code 88 Brake Band Apply Solenoid Malfunction....1721
DTC P1860/Flashing Code 89 TCC Solenoid Electrical....1725
7B MANUAL TRANSMISSION....1728
Service Precaution....1728
General Description....1729
Diagnosis (MUA)....1731
Transmission (MUA)....1732
Disassembled View....1732
Removal....1732
Installation....1737
Transmission Case and Transfer Case....1742
Major Component (MUA)....1742
Disassembly....1743
Reassembly....1746
Intermediate Plate with Gear Assembly, Detent, Shift Arm, and Inter-lock Pin (MUA)....1752
Disassembled View....1752
Disassembly....1753
Inspection and Repair....1754
Reassembly....1755
Reverse Gear and 5th Gear (MUA)....1756
Disassembled View....1756
Disassembly....1757
Inspection and Repair....1759
Reassembly....1759
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft (MUA)....1765
Disassmebled View....1765
Disassembly....1766
Inspection and Repair....1767
Reassembly....1770
Main Data and Specifications....1776
Special Tools (MUA)....1780
7C CLUTCH....1782
Service Precaution....1782
General Description....1783
Diagnosis....1789
Clutch Assembly (X22SE, MUA)....1790
Clutch Assembly (X22SE, MUA) and Associated Parts....1790
Removal....1790
Inspection and Repair....1791
Installation....1794
Clutch Assembly (6VD1, MUA)....1796
Clutch Assembly (6VD1, MUA) and Associated Parts....1796
Removal....1796
Inspection and Repair....1798
Installation....1802
Clutch Control....1804
Parts Location View....1804
Removal....1805
Inspection and Repair....1805
Installation....1806
Master Cylinder....1808
Disassembly....1808
Inspection and Repair....1808
Reassembly....1808
Slave Cylinder....1809
Disassembled View....1809
Disassembly....1809
Inspection and Repair....1809
Reassembly....1810
Damper Cylinder....1811
Disassembled View....1811
Disassembly....1811
Inspection and Repair....1811
Reassembly....1811
Main Data and Specifications....1812
Special Tools....1814
Sec.8 BODY AND ACCESSORIES....1815
8A LIGHTING SYSTEM....1815
Service Precaution....1816
Headlight Bulb....1817
Removal....1817
Installation....1817
Headlight Assembly....1817
Removal....1817
Installation....1817
Headlight Adjustment....1818
Fog Light Bulb....1818
Removal....1818
Installation....1818
Fog Light Assembly....1819
Removal....1819
Installation....1819
Fog Light Adjustment....1819
Clearance Light Bulb....1819
Removal....1819
Installation....1819
Front Combination Light Assembly....1820
Removal....1820
Installation....1820
Taillight Bulb....1820
Removal....1820
Installation....1820
License Plate Light Bulb (Bumper Type)....1821
Removal....1821
Installation....1821
License Plate Light Bulb (Tailgate Type)....1821
Removal....1821
Installation....1821
Stoplight Bulb....1822
Removal....1822
Installtion....1822
High Mounted Stoplight Assembly (4Door Model)....1822
Removal....1822
Installation....1822
High Mounted Stoplight Bulb (4Door Model)....1823
Removal....1823
Installation....1823
High Mounted Stoplight Assembly (2Door Model)....1823
Removal....1823
Installation....1823
High Mounted Stoplight Bulb (2Door Model)....1824
Removal....1824
Installation....1824
Backup Light Bulb....1824
Removal....1824
Installation....1824
Front Turn Signal Light Bulb....1825
Removal....1825
Installation....1825
Side Turn Signal Light Bulb....1825
Removal....1825
Installation....1825
Rear Turn Signal Light Bulb....1826
Removal....1826
Installation....1826
Dome Light Bulb....1826
Removal....1826
Installation....1826
Courtesy Light Bulb....1827
Removal....1827
Installation....1827
Map Light Bulb....1827
Removal....1827
Installation....1827
Luggage Room Light Bulb (4Door Model)....1828
Removal....1828
Installation....1828
Luggage Room Light Bulb (2Door Model)....1828
Removal....1828
Installation....1828
HVAC Bezel Illumination Light Bulb....1829
Removal and Installation....1829
Shift Lever Illumination Light Bulb (A/T)....1829
Removal....1829
Installation....1829
Ashtray Illumination Bulb....1830
Removal....1830
Installation....1830
Starter Switch....1830
Removal and Installation....1830
Lighting Switch (Combination Switch)....1830
Removal and Installation....1830
DimmerｷPassing Switch (Combination Switch)....1830
Removal and Installation....1830
Door Switch....1831
Removal....1831
Installation....1831
Rear Defogger Switch....1831
Removal....1831
Installation....1831
Key Remind Switch (Starter Switch)....1832
Removal and Installation....1832
Hazard Warning Light Switch....1832
Removal and Installation....1832
Stoplight Switch....1832
Removal....1832
Installation....1832
4WD Switch....1833
Removal....1833
Installation....1833
Backup Light Switch (M/T)....1833
Removal....1833
Installation....1833
Turn Signal Light Switch (Combination Switch)....1833
Removal and Installation....1833
Light and Bulb Specifications (4Door Model ｷ Spear Tire Under Mount Type)....1834
Light and Bulb Specifications (4Door Model ｷ Spear Tire Tail Gate Type)....1835
Light and Bulb Specifications (2Door Model)....1836
8B WIPER / WASHER SYSTEM....1838
Service Precaution....1838
Windshield Wiper/Washer System....1839
General Description....1839
Windshield Wiper And Washer Switch....1839
Removal and Installation....1839
Windshield Wiper Motor....1839
Removal....1839
Installation....1839
Windshield Washer Motor....1840
Removal....1840
Installation....1840
Windshield Washer Spray Pattern....1841
Windshield Wiper Linkage....1842
Windshield Wiper Linkage and Associated Parts....1842
Removal....1842
Installation....1842
Windshield Wiper Arm/Blade....1843
Removal....1843
Installation....1843
Windshield Wiper Blade Rubber....1844
Removal....1844
Installation....1844
Rear Wiper/Washer System....1845
General Description....1845
Rear Wiper and Washer Switch....1845
Removal....1845
Installation....1845
Rear Wiper Motor (4Door Model)....1846
Removal....1846
Installation....1846
Rear Wiper Motor (2Door Model)....1847
Removal....1847
Installation....1847
Rear Washer Motor....1848
Removal....1848
Installation....1848
Alarm and Relay Control Unit....1848
Removal....1848
Installation....1848
Rear Wiper Arm/Blade (4Door Model)....1849
Removal....1849
Installation....1849
Rear Wiper Arm/Blade (2Door Model)....1849
Removal....1849
Installation....1849
Rear Washer Nozzle (4Door Model)....1850
Removal....1850
Installation....1850
Rear Washer Spray Pattern....1850
Rear Washer Nozzle (2Door Model)....1851
Removal....1851
Installation....1851
Rear Washer Spray Pattern....1851
Rear Wiper Blade Rubber....1852
Removal....1852
Installation....1852
Main Data and Specifications....1853
8C ENTERTAINMENT....1854
Service Precaution....1854
Cigarette Lighter....1855
General Description....1855
Removal....1855
Installation....1855
Digital Clock....1855
Removal....1855
Installation....1856
Rod Type Antenna....1856
Removal....1856
Installation....1856
Radio....1857
Removal....1857
Installation....1857
Speaker....1858
Front Speaker....1858
Tweeter Assembly....1858
Rear Speaker (4Door Model)....1858
Rear Speaker (2Door Model)....1859
Accessory Socket....1859
Front Accessory Socket....1859
Rear Accessory Socket....1859
Horn....1860
Removal....1860
Installation....1860
8D WIRING SYSTEM....1861
Service Precaution....1862
General Description....1863
Main Data and Specifications....1885
Fuse, Fusible Link and Circuit Breaker Location....1885
Relay & Fuse Box (Engine Room)....1886
Relay & Fuse Box (Instrument panel)....1886
Fuse Block Circuit ....1887
Reference Table of Fuse, Fusible Link and Circuit Breaker....1893
Relay Location....1895
Diode Location....1897
Grounding Point....1899
Cable Harness Routing....1903
Start and Charging....1906
General Description....1906
Circuit Diagram....1907
Parts Location....1909
Powertrain Control Module (PCM)....1910
General Description....1910
Circuit Diagram....1911
Parts Location....1924
Circuit Diagram....1927
Parts Location....1937
Headlight and Fog Light....1939
General Description....1939
Circuit Diagram....1940
Parts Location....1942
Diagnosis....1943
Clearance Light, Tail Light and License Plate Light....1947
General Description....1947
Circuit Diagram....1948
Parts Location....1950
Diagnosis....1951
Interior Illumination Light....1953
General Description....1953
Circuit Diagram....1954
Parts Location....1957
Diagnosis....1958
Turn Signal Light, Hazard Warning Light....1959
General Description....1959
Circuit Diagram....1960
Parts Location....1962
Diagnosis....1963
Stoplight....1965
General Description....1965
Circuit Diagram....1966
Parts Location (2Door Model)....1967
Diagnosis....1969
Backup Light....1971
General Description....1971
Circuit Diagram....1972
Parts Location....1973
Diagnosis....1974
Horn....1976
General Description....1976
Circuit Diagram....1977
Parts Location....1978
Diagnosis....1979
Dome Light, Luggage Room Light, Courtesy Light, Map Light, Seat Belt Switch and Warning Buzzer....1980
General Description....1980
Circuit Diagram....1981
Parts Location....1987
Diagnosis....1988
Power Door Lock....1989
General Description....1989
Circuit Diagram....1990
Parts Location....1993
Diagnosis....1994
Power Window....1996
General Description....1996
Circuit Diagram....1997
Parts Location....1998
Diagnosis....1999
Cruise Control....2004
General Description....2004
Circuit Diagram....2005
Parts Location....2007
Diagnosis....2008
Anti‐Lock Brake System (ABS)....2012
General Description....2012
Circuit Diagram....2013
Parts Location....2015
A/T Shift Lock....2016
General Description....2016
Circuit Diagram....2017
Parts Location....2018
Windshield Wiper and Washer....2019
General Description....2019
Circuit Diagram....2020
Parts Location....2023
Diagnosis....2024
Rear Wiper/Washer....2030
General Description....2030
Circuit Diagram....2031
Parts Location....2036
Diagnosis....2037
Rear Defogger/Mirror Defogger....2041
General Description....2041
Circuit Diagram....2042
Diagnosis....2047
Audio....2050
General Description....2050
Circuit Diagram....2051
Parts Location....2052
Cigarette Lighter, Digital Clock and Accessory Socket....2053
General Description....2053
Circuit Diagram....2054
Parts Location....2055
Diagnosis....2056
Power Door Mirror....2057
General Description....2057
Circuit Diagram....2058
Parts Location....2060
Diagnosis....2061
Keyless Entry....2063
General Description....2063
Circuit Diagram....2064
Parts Location....2068
Keyless Entry System....2069
Meter and Warning/Indicator Light....2070
General Description....2070
Circuit Diagram....2071
Parts Location....2078
Diagnosis....2079
A/T Shift Indicator....2084
General Description....2084
Circuit Diagram....2085
Parts Location....2087
Heater and Air Conditioning....2088
General Description....2088
Circuit Diagram....2089
Parts Location....2091
Heater and Air Conditioning....2092
General Description....2092
Circuit Diagram....2093
Parts Location....2099
Sunroof....2100
General Description....2100
Circuit Diagram....2101
Parts Location....2102
Diagnosis....2103
Supplemental Restraint System (SRS)-Air Bag....2104
General Description....2104
Circuit Diagram....2105
Parts Location....2106
Shift on the Fly System....2107
General Description....2107
Circuit Diagram....2109
Parts Location....2111
Harness Connector Faces....2112
8E METER AND GAUGE....2129
Service Precaution....2129
Meter Assembly....2130
General Description....2130
Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination Lights....2130
Table for Meter/Gauge Connector Terminal Connections....2134
Removal....2138
Installation....2138
Warning Light Bulb, Indicator Light Bulb, Illumination Light Bulb, A/T Shift Indicator Light Bulb....2138
Removal....2138
Installation....2138
Vehicle Speed Sensor....2139
Removal....2139
Installation....2139
Fuel Tank Unit....2139
Removal....2139
Installation....2139
Main Data and Specifications....2140
8F BODY STRUCTURE....2141
Service Precaution....2142
Frame....2143
General Description....2143
Frame Dimensions (LWB)....2143
Frame Dimensions (SWB)....2144
General Description (Bumper)....2145
Front Bumper....2145
Parts Location....2145
Removal....2146
Installation....2146
Front Bumper Slider Bracket....2147
Removal....2147
Installation....2147
Rear Bumper....2148
Parts Location....2148
Removal....2149
Installation....2149
Rear Bumper Slider....2150
Removal....2150
Installation....2150
General Description (Sheet Metal)....2151
Engine Hood....2151
Parts Location....2151
Removal....2152
Installation....2152
Engine Hood Lock....2154
Parts Location....2154
Removal....2154
Installation....2155
Radiator Grille....2156
Parts Location....2156
Removal....2156
Installation....2157
Front Fender Panel....2158
Parts Location....2158
Removal....2158
Installation....2159
Body Mounting....2161
Parts Location....2161
Tightening Torque....2161
Body Dimension....2162
Front Section....2162
Room Section (SWB)....2165
Room Section (LWB)....2167
Rear Section (SWB)....2169
Rear Section (LWB)....2171
Side Body Section (Front side)....2173
Side Body Section (Rear side)....2175
General Description (Body)....2177
Instrument Panel Assembly....2177
Parts Location....2177
Removal....2178
Installation....2180
Front Door Assembly....2181
Parts Location....2181
Removal....2181
Installation....2182
Rear Door Assembly....2183
Parts Location....2183
Removal....2183
Installation....2184
Front Window Regulator, Glass and Glass Run....2185
Parts Location....2185
Removal....2186
Installation....2187
Rear Window Regulator, Glass and Glass Run....2188
Parts Location....2188
Removal....2189
Installation....2190
Rear Tailgate (LWB)....2191
Parts Location....2191
Removal....2192
Installation....2193
Rear Tailgate (SWB)....2194
Parts Location....2194
Removal....2194
Installation....2195
Rear Hatchgate (LWB)....2196
Parts Location....2196
Removal....2197
Installation....2197
Adjustment....2199
Tailgate Glass (SWB)....2200
Parts Location....2200
Removal....2200
Installation....2201
Spare Tire Carrier....2202
Parts Location....2202
Removal....2202
Installation....2202
Windshield....2203
Parts Location....2203
Removal....2203
Installation....2204
Rear Quarter Glass (LWB)....2207
Parts Location....2207
Removal....2207
Installation....2208
Rear Quarter Glass (SWB)....2209
Parts Location....2209
Removal....2209
Installation....2209
Side Window Glass (SWB)....2211
Parts Location....2211
Removal....2211
Installation....2211
Main Data and Specifications....2213
Special Tools....2216
8G SEATS....2217
Service Precaution....2217
Front Seat Assembly....2218
Front Seat Assembly and Associated Parts....2218
Removal....2218
Installation....2220
Rear Seat Assembly (LWB)....2221
Rear Seat Cushion Assembly and Associated Parts....2221
Removal....2221
Installation....2222
Rear Seat Back Assembly and Associated Parts....2223
Removal....2223
Installation....2224
Rear Seat Assembly (SWB)....2225
Rear Seat Assembly and Associated Parts....2225
Removal....2226
Installation....2226
Main Data and Specifications....2227
Torque Specifications....2227
8H SECURITY AND LOCKS....2229
Service Precaution....2229
Front Door Lock Assembly....2230
Front Door Lock Assembly and Associated Parts....2230
Removal....2231
Installation....2232
Front Outside Handle....2233
Front Outside Handle and Associated Parts....2233
Removal....2233
Installation....2233
Rear Door Lock Assembly....2234
Rear Door Lock Assembly and Associated Parts....2234
Removal....2235
Installation....2235
Rear Outside Handle....2236
Rear Outside Handle and Associated Parts....2236
Removal....2236
Installation....2236
Tailgate Lock and Hatchgate Lock (LWB)....2237
Tailgate Lock, Hatchgate Lock and Associated Parts....2237
Removal....2238
Installation....2239
Tailgate Lock (SWB)....2240
Tailgate Lock and Associated Parts....2240
Removal....2240
Installation....2241
Fuel Filler Door Lock....2242
Fuel Filler Door Lock and Associated Parts....2242
Removal....2242
Installation....2243
Key....2244
Key Coding....2244
Key Styles....2244
Power Door Lock System....2245
General Description....2245
Door Lock Key Switch....2245
Front Door Lock Actuator....2245
Rear Door Lock Actuator....2245
Tailgate Lock Actuator....2245
Fuel Filler Door Lock Actuator....2245
Keyless Entry System....2246
General Description....2246
Keyless Entry Control Unit....2246
Keyless Entry Control Unit/Transmitter Replacement....2246
Main Data and Specifications....2247
8I SUNROOF/CONVERTIBLE TOP....2248
Service Precaution....2248
Sunroof Glass (LWB)....2249
Sunroof Glass and Associated Parts....2249
Removal....2249
Installation....2250
Sunroof Glass (SWB)....2250
Sunroof Glass and Associated Parts....2250
Removal....2251
Installation....2251
Sunroof Deflector (LWB)....2252
Removal....2252
Installation....2252
Sunroof Deflector (SWB)....2253
Parts Location....2253
Removal....2253
Installation....2253
Sunshade (LWB)....2254
Disassembled View....2254
Removal....2254
Installation....2255
Sunroof Frame Complete Assembly (LWB)....2256
Sunroof Frame Complete Assembly and Associated Parts....2256
Removal....2256
Installation....2257
Sunroof Switch....2257
Removal....2257
Installation....2257
Sunroof Control Unit....2258
Removal....2258
Installation....2258
Safety Stop Switch....2258
Removal....2258
Installation....2258
Limit Switch....2259
Removal....2259
Installation....2259
Sunroof Motor....2259
Removal....2259
Installation....2259
Resin Top Assembly....2260
Resin Top Assembly and Associated Parts....2260
Removal....2260
Installation....2261
Seat Belt Cross Bar Assembly....2262
Seat Belt Cross Bar Assembly and Associated Parts....2262
Removal....2262
Installation....2263
Main Data and Specifications....2264
8J EXTERIOR / INTERIOR TRIM....2265
Service Precaution....2265
Consoles....2266
Consoles and Associated Parts....2266
Removal....2266
Installation....2266
Front Door Trim Panel....2267
Front Door Trim Panel and Associated Parts....2267
Removal....2268
Installation....2268
Rear Door Trim Panel....2269
Rear Door Trim Panel and Associated Parts....2269
Removal....2270
Installation....2270
Interior Trim Panels (LWB)....2271
Interior Trim Panels and Associated Parts....2271
Removal....2271
Installation....2272
Interior Trim Panels (SWB)....2273
Interior Trim Panels and Associated Parts....2273
Removal....2273
Installation....2274
Headlining (LWB)....2275
Parts Location....2275
Removal....2275
Installation....2276
Headlining (SWB)....2277
Parts Location....2277
Removal....2278
Installation....2278
Wheel Arch Protector (LWB)....2279
Wheel Arch Protector and Associated Parts....2279
Removal....2279
Installation....2279
Wheel Arch Protector (SWB)....2280
Wheel Arch Protector and Associated Parts....2280
Removal....2280
Installation....2280
Wheel Arch Moulding (SWB)....2281
Wheel Arch Moulding and Associated Parts....2281
Removal....2281
Installation....2282
Fuel Filler Door....2283
Parts Location....2283
Removal....2283
Installation....2283
Roof Rail....2284
Parts Location....2284
Removal....2284
Installation....2284
Power Door Mirror System....2285
General Description....2285
Door Mirror Switch....2285
Power Window System....2286
General Description....2286
Power Window Switch Driver Seat Side....2286
Power Window Motor....2287
Main Data and Specifications....2289
Sec.9 RESTRAINTS....2290
9A SEAT BELT SYSTEM....2290
Service Precaution....2290
Front Seat Belt (LWB)....2291
Front Seat Belt and Associated Parts....2291
Removal....2291
Inspection....2291
Installation....2292
Front Seat Belt (SWB)....2293
Front Seat Belt and Associated Parts....2293
Removal....2293
Inspection....2294
Installation....2294
Rear Seat Belt (LWB)....2295
Rear Seat Belt and Associated Parts....2295
Removal....2295
Inspection....2296
Installation....2297
Rear Seat Belt (SWB)....2298
Rear Seat Belt and Associated Parts....2298
Removal....2298
Inspection....2299
Installation....2299
Front Seat Buckle Assembly....2300
Removal....2300
Installation....2300
Rear Center Seat Belt / Buckle Assembly....2301
Rear Center Seat Belt / Buckle Assembly and Associated Parts....2301
Removal....2301
Installation....2301
Child Seat Tether Anchor Bracket (Child Restraint)....2302
General Description....2302
Child Seat Tether Anchor Bracket and Associated Parts....2302
Installation....2302
Main Data and Specifications....2303
9J SUPPLEMENTAL RESTRAINT SYSTEM(Air Bag System)....2305
Service Precaution....2305
General Description....2306
SRS Component and Wiring Location View....2308
Component Description....2308
Definition....2311
Diagnosis....2312
SRS Connector Body Face Views....2313
On-Vehicle Service....2314
Air Bag Assembly Handling / Shipping / Scrapping....2315
Special Tools....2331
Service Precaution....2337
Sensing and Diagnostic Module (SDM)....2339
Service Precautions....2339
Removal....2339
Installation....2339
Driver Air Bag Assembly....2341
Service Precautions....2341
Removal....2341
Installation....2341
Steering Wheel....2342
Service Precautions....2342
Removal....2342
Installation....2343
SRS Coil Assembly....2344
Service Precaution....2344
Removal....2344
How to Disconnect the horn terminal....2346
How to Connect Horn Terminal....2346
Installation....2347
Steering Column....2349
Service Precaution....2349
Removal....2349
Installation....2351
Passenger Air Bag Assembly....2353
Service Precaution....2353
Removal....2353
Installation....2353
Main Data and Specifications....2354
SRS Air Bag System Inspection Standards For Repair....2355
9J1 SRS CONTROL SYSTEM....2356
Service Precaution....2356
Diagnostic Information....2357
Parts For Electrical Circuit Wiring....2359
System Schematic....2360
SRS Diagnostic System Check....2360
Chart A SDM Integrity Check....2364
Chart B "AIR BAG" Warning Lamp Comes "ON" Steady....2366
Chart C "AIR BAG" Warning Lamp Does Not Comes "ON" Steady....2368
DTC 15 Passenger Deployment Loop Resistance High....2371
DTC 16 Passenger Deployment Loop Resistance Low....2374
DTC 17 Passenger Deployment Loop Open....2377
DTC 18 Passenger Deployment Loop Short To Ground....2380
DTC 19 Passenger Deployment Loop Short To Voltage....2383
DTC 21 Driver Deployment Loop Resistance High....2386
DTC 22 Driver Deployment Loop Resistance Low....2389
DTC 24 Driver Deployment Loop Short To Ground....2392
DTC 25 Driver Deployment Loop Short To Voltage....2395
DTC 26 Driver Deployment Loop Open....2399
DTC 51 Deployment Event Commanded....2402
DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy Reserves Out Of Range....2404
DTC 61 Warning Lamp Circuit Failure....2407
DTC 71 Internal SDM Fault....2409
Sec.10 CONTROL SYSTEMS....2411
10A CRUISE CONTROL SYSTEM....2411
Service Precaution....2411
General Description....2412
Diagnosis....2412
Brake Switch....2413
Removal and Installation....2413
Adjustment....2413
Clutch Switch....2413
Removal and Installation....2413
Adjustment....2413
Cruise Control Unit....2414
Removal....2414
Installation....2414
Cruise Actuator....2415
Actuator Cable Diagram....2415
Removal....2415
Installation....2415
Adjustment....2416
Mode Switch....2416
Removal and Installation....2416
Cruise Control Main Switch....2416
Removal....2416
Installation....2416
Cruise Control Switch (Combination Switch)....2417
Removal and Installation....2417
2000 MODEL....2
(UE) FRONTERA....2418
Sec.0 GENERAL INFORMATION....2419
0A GENERAL INFORMATION....2419
General Repair Instruction....2419
Illustration Arrows....2420
Identification....2421
Lifting Instructions....2423
Standard Bolts Torque Specifications....2426
Abbreviations Charts....2427
Service Parts Identification Plate....2429
0B MAINTENANCE AND LUBRICATION....2430
Maintenance Schedule List....2430
Service and Maintenance....2431
Recommended Fluids and Lubricants....2438
Lubricant Viscosity Chart....2439
Recommended Liquid Gasket....2441
Recommended Thread Locking Agents....2442
Maintenance Service Data....2443
Sec.1 HEATING, VENTILATION AND AIR CONDITIONING....2444
1A HVAC SYSTEMS....2444
Service Precaution....2446
Heating and Ventilation System....2446
General Description....2446
Heater and Ventilation Associated Parts....2447
Ventilation....2448
Circuit Diagram....2451
Diagnosis....2452
Individual Inspection....2456
Heater Unit....2458
Heater Unit and Associated Parts....2458
Removal....2458
Installation....2459
Heater Core and / or Mode Door....2459
Disassembled View....2459
Removal....2459
Inspection....2460
Installation....2460
Heater Mode Control Link Unit....2461
Disassembled View....2461
Removal....2461
Installation....2462
Heater Temperature Control Link Unit....2462
Disassembled View....2462
Removal....2462
Installation....2463
Blower Assembly....2463
Blower Assembly and Associated Parts....2463
Removal....2464
Installation....2464
Blower Link Unit and / or Mode door....2464
Disassembled View....2464
Removal....2464
Installation....2465
Blower Motor....2466
Blower Motor and Associated Parts....2466
Removal....2466
Installation....2466
Rear Heater Duct, Defroster Nozzle and Ventilation Duct....2467
Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts....2467
Removal....2467
Installation....2468
Control Lever Assembly and / or Control Cable....2468
Control Lever Assembly, Control Cable and Associated Parts....2468
Removal....2469
Installation....2470
Control Panel Illumination Bulb....2471
Control Panel Illumination Bulb and Associated Parts....2471
Installation....2471
Resistor....2471
Resistor and Associated Parts....2471
Removal....2471
Installation....2471
Air Conditioning System....2472
General Description....2472
Circuit Diagram....2479
Diagnosis....2481
Individual Inspection....2489
General Repair Procedure....2490
Leak Check....2491
Compressor Assembly....2497
Compressor Assembly and Associated Parts (6VD1)....2497
Removal....2497
Installation....2498
Compressor Assembly and Associated Parts (X22SE)....2499
Removal....2499
Installation....2500
New Compressor Installation....2500
Condenser Assembly....2501
Condenser Assembly and Associated Parts....2501
Removal....2501
Installation....2501
Condenser Fan Motor....2502
Condenser Fan Motor and Associated Parts....2502
Removal....2502
Installation....2502
Receiver / Drier....2503
Receiver / Drier and Associated Parts....2503
Removal....2503
Installation....2503
Pressure Switch....2504
Pressure Switch and Associated Parts....2504
Removal....2504
Installation....2504
Evaporator Assembly....2505
Evaporator Assembly and Associated Parts....2505
Removal....2505
Installation....2506
Electronic Thermostat, Evaporator Core and/or Expansion Valve....2507
Disassembled View....2507
Removal....2507
Installation....2508
Refrigerant Line....2509
Refrigerant Line and Associated Parts....2509
Removal....2509
Installation....2510
Main Data And Specifications....2511
Compressor....2514
Service Precaution....2514
General Description....2514
Diagnosis....2515
Magnetic Clutch Assembly (DKV-14G Type)....2516
Parts Location View....2516
Removal....2516
Inspection and Repair....2518
Installation....2518
Compressor Oil....2520
Oil Specification....2520
Handling of Oil....2520
Compressor Oil Check....2520
Checking and Adjusting Oil Quantity for Used Compressor....2520
Checking and Adjusting for Compressor Replacement....2521
Contamination of Compressor Oil....2521
Oil Return Operation....2521
Replacement of Component Parts....2521
Main Data and Specifications....2522
Special Tools....2524
Automatic Air Conditioning System....2525
General Description....2525
Automatic Air Conditioner Parts Configuration....2525
Refrigerant Line and Associated Parts....2526
Circuit Diagram....2527
Functions and Features....2533
Automatic Air Conditioner Block Diagram....2534
Control Panel Layout....2535
Air Control Functions....2536
Operation and Functions of Control Panel Switches....2537
Overview of Construction, Movement and Control of Major Parts of Automatic Air Conditioner System....2540
Overview of Automatic Control of Automatic Air Conditioner....2543
Troubleshooting....2547
Troubleshooting, Its Overview and Procedures....2547
Auto Air Conditioner Control Unit Power Supply Diagnosis....2548
Performance and Movement checklist for Automatic Air Conditioner Related Parts....2550
Troubleshooting With Self-Diagnosis Function....2552
Inspection By Failed Location....2556
Inspection of the Sensors....2556
Inspection of the Intake Actuator System....2560
Inspection of the Mix Actuator System....2563
Inspection of the Mode Actuator System....2566
Inspection of the Fan Motor System....2569
Inspection of the Magnetic Clutch System....2573
Condenser Fan Diagnosis....2576
Individual Inspection....2579
On-Vehicle Service....2583
Power Transistor....2583
Removal....2583
Installation....2583
Automatic Heater/Air Conditioner Control Unit....2583
Removal....2583
Installation....2583
In Car Sensor....2584
Removal....2584
Installation....2584
Ambient Sensor....2584
Removal....2584
Installation....2584
Sun Sensor....2585
Removal....2585
Installation....2585
Electronic Thermostat....2585
Removal....2585
Installation....2585
Mode Actuator....2586
Removal....2586
Installation....2586
Mix Actuator....2586
Removal....2586
Installation....2586
Intake Actuator....2587
Removal....2587
Installation....2587
Sec.2 STEERING....2588
2A POWER-ASSISTED STEERING SYSTEM....2588
Service Precaution....2589
Diagnosis....2589
General Description....2595
Power Steering System Test....2597
Maintenance....2598
Fluid Level....2598
Bleeding The Power Steering System....2598
Bleeding Procedure....2598
Flushing The Power Steering System....2599
Steering Wheel Free Play Inspection....2599
Front End Alignment Inspection and Adjustment....2599
Main Data and Specifications....2603
Special Tools....2604
Power Steering Unit....2605
Power Steering Unit and Associated Parts....2605
Removal....2605
Installation....2606
Power Steering Unit Disassembled View....2607
Disassembly....2607
Inspection and Repair....2607
Reassembly....2607
Main Data and Specifications....2608
Special Tools....2608
Power Steering Pump....2609
Power Steering Pump and Associated Parts....2609
Removal....2609
Installation....2609
Power Steering Pump Disassembled View....2610
Disassembly....2610
Inspection and Repair....2611
Reassembly....2611
Main Data and Specifications....2613
Transfer Gear Assembly....2614
Transfer Gear Assembly and Associated Parts....2614
Removal....2614
Inspection and Repair....2614
Installation....2614
Supplemental Restraint System Steering Wheel & Column....2615
Service Precaution....2615
SRS Connectors....2615
Inflator Module....2617
Inflator Module and Associated Parts....2617
Removal....2617
Inspection and Repair....2618
Installation....2618
Steering Wheel....2619
Steering Wheel and Associated Parts....2619
Removal....2619
Installation....2621
Combination Switch....2622
Combination Switch and Associated Parts....2622
Removal....2622
Installation....2624
Lock Cylinder....2626
Lock Cylinder and Associated Parts....2626
Removal....2626
Installation....2628
System Inspection....2629
Steering Column....2630
Steering Column and Associated Parts....2630
Removal....2630
Insepction....2633
Installation....2634
System Inspection....2635
Supplemental Restraint System Steering Wheel & Column and Associated Parts....2636
Main Data and Specifications....2636
Special Tools....2636
Sec.3 SUSPENSION....2637
3C FRONT SUSPENSION....2637
Service Precaution....2637
General Description....2638
Diagnosis....2638
Shock Absorber....2641
Shock Absorber and Associated Parts....2641
Removal....2641
Inspection and Repair....2641
Installation....2641
Stabilizer Bar....2642
Stabilizer Bar and Associated Parts....2642
Removal....2642
Inspection and Repair....2642
Installation....2642
Shock Absorber....2641
Shock Absorber and Associated Parts....2641
Removal....2641
Inspection and Repair....2641
Installation....2641
Stabilizer Bar....2642
Stabilizer Bar and Associated Parts....2642
Removal....2642
Inspection and Repair....2642
Installation....2642
Torsion Bar....2643
Torsion Bar and Associated Parts....2643
Removal....2643
Inspection and Repair....2644
Installation....2644
Knuckle....2646
Knuckle and Associated Parts....2646
Removal....2646
Inspection and Repair....2647
Installation....2647
Upper Control Arm....2649
Upper Control Arm and Associated Parts....2649
Removal....2649
Inspection and Repair....2650
Installation....2650
Lower Control Arm....2653
Lower Control Arm and Associated Parts....2653
Removal....2653
Inspection and Repair....2654
Installation....2655
Upper Ball Joint....2657
Upper Ball Joint and Associated Parts....2657
Removal....2657
Inspection and Repair....2658
Installation....2658
Lower Ball Joint....2659
Lower Ball Joint and Associated Parts....2659
Removal....2659
Inspection and Repair....2660
Installation....2660
Main Data and Specifications....2661
Special Tools....2662
3D REAR SUSPENSION....2663
Service Precaution....2663
General Description....2663
Diagnosis....2664
Coil Spring....2667
Coil Spring and Associated Parts....2667
Removal....2667
Inspection and Repair....2668
Installation....2668
Shock Absorber....2669
Removal....2669
Inspection and Repair....2669
Installation....2669
Trailing Link....2670
Trailing Link and Associated Parts....2670
Removal....2670
Inspection and Repair....2670
Installation....2671
Upper Link....2672
Upper Link and Associated Parts....2672
Removal....2672
Inspection and Repair....2672
Installation....2673
Lateral Rod....2674
Lateral Rod and Associated Parts....2674
Removal....2674
Inspection and Repair....2674
Installation....2675
Stabilizer Bar....2676
Stabilizer Bar and Associated Parts....2676
Removal....2676
Inspection and Repair....2676
Installation....2677
Main Data and Specifications....2678
Special Tools....2680
3E WHEEL AND TIRE SYSTEM....2681
Service Precaution....2681
General Description....2682
Diagnosis....2683
Wheel....2691
Wheel and Associated Parts....2691
Removal....2691
Installation....2691
Tire....2692
Tire Replacement....2692
General Balance Procedure....2692
Balancing Wheel and Tire....2693
Main Data and Specifications....2694
Sec.4 DRIVELINE/AXLE....2695
4A1 DIFFERENTIAL (FRONT)....2695
Service Precaution....2695
Front Drive Axle....2696
Diagnosis....2696
Pinion Shaft Oil Seal....2697
Pinion Shaft Oil Seal and Associated Parts....2697
Removal....2697
Inspection and Repair....2698
Installation....2698
Front Drive Axle Assembly....2699
Front Drive Axle Assembly and Associated Parts....2699
Removal....2700
Installation....2701
Differential Assembly....2702
Disassembled View....2702
Disassembly....2703
Reassembly....2705
Differential Cage Assembly....2714
Disassembled View....2714
Disassembly....2714
Inspection and Repair....2715
Reassembly....2716
Main Data and Specifications....2718
Special Tools....2721
4A2 DIFFERENTIAL (REAR)....2723
Service Precaution....2723
General Description....2724
Diagnosis....2725
Axle Housing....2727
Axle Housing and Associated Parts....2727
Removal....2727
Installation....2729
Axle Shaft, Oil Seal and Bearing....2729
Axle Shaft and Associated Parts....2729
Removal....2729
Inspection....2730
Installation....2730
Pinion Oil Seal....2732
Pinion Oil Seal and Associated Parts....2732
Removal....2732
Inspection and Repair....2733
Installation....2733
Differential Assembly....2735
Disassembled View....2735
Inspecting the Axle Before Disassembly....2736
Disassembly....2736
Inspection and Repair....2738
Reassembly....2739
Side Bearing Preload Adjustment....2743
Pinion Installation....2744
Determination of Backlash & Preload Shims....2745
Backlash Adjustment....2746
Gear Tooth Pattern Check....2747
Adjustments Affecting Tooth Contact....2748
Differential Case Assembly....2749
Disassembled View....2749
Disassembly....2750
Inspection and Repair....2750
Reassembly....2750
Limited Slip Differential Assembly....2751
Disassembled View....2751
Disassembly....2751
Inspection and Repair....2753
Reassembly....2753
Main Data And Specifications....2755
Special Tools....2757
4B DRIVELINE CONTROL SYSTEM....2759
Service Precaution....2759
Shift On The Fly System....2760
Outline of Shift on The Fly System....2760
Functions of Indicator Lamp....2764
Diagnosis....2765
Shift On The Fly Vacuum Piping and Electrical Equipment....2776
Vacuum Piping Diagram....2776
Actuator Assembly....2776
Vacuum Tank....2776
Inspection and Repair....2777
4WD Control Unit....2780
4WD Control Unit Associated Parts....2780
Removal....2781
Installation....2781
4C DRIVE SHAFT SYSTEM....2782
Service Precaution....2782
General Description....2783
Diagnosis....2783
Front Hub and Disc....2784
Disassembled View....2784
Disassembly....2784
Inspection and Repair....2785
Reassembly....2786
Front Drive Shaft Joint....2789
Front Drive Shaft Joints Replacement....2789
Front Axle Drive Shaft....2790
Front Axle Drive Shaft and Associated Parts....2790
Disassembly....2791
Inspection And Repair....2792
Bushing Replacement....2792
Reassembly....2792
Shift On The Fly System....2795
Shift On The Fly System and Associated Parts....2795
Disassembly....2795
Inspection And Repair....2797
Reassembly....2800
Main Data and Specifications....2803
Special Tools....2805
Propeller Shaft....2806
General Description....2806
Universal Joint....2807
Diagnosis of Propeller Shaft and Universal Joint....2808
Front Propeller Shaft....2809
Front Propeller Shaft and Associated Parts....2809
Removal....2809
Installation....2810
Slip Joint Disassembly....2810
Universal Joint Disassembly (Single Cardan Type)....2811
Universal Joint Disassembly (Double Cardan Type)....2813
Inspection and Repair....2814
Universal Joint Reassembly (Single Cardan Type)....2816
Universal Joint Reassembly (Double Cardan Type)....2817
Slip Joint Reassembly....2819
Main Data and Specifications....2820
Rear Propeller Shaft....2821
Rear Propeller Shaft and Associated Parts....2821
Removal....2821
Installation....2821
Slip Joint Disassembly....2822
Universal Joint Disassembly....2823
Inspection....2825
Universal Joint Reassembly....2826
Slip Joint Reassembly....2827
Main Data and Specifications....2828
4D TRANSFER CASE....2829
Service Precaution....2829
General Description....2830
Transfer Rear Oil Seal....2832
Transfer Rear Oil Seal and Associated Parts....2832
Removal....2832
Installation....2832
Transfer Case Assembly (A/T)....2834
Transfer Case Assembly (A/T) and Associated Parts....2834
Removal....2835
Installation....2836
Transfer Rear Case Assembly (A/T)....2839
Transfer Rear Case Assembly (A/T) and Associated Parts....2839
Removal....2839
Installation....2841
Transfer Rear Cover Assembly....2844
Disassembly....2844
Inspection and Repair....2845
Reassembly....2845
Detent, Shift Arm, and Interlock Pin (Transfer Case Assembly)....2847
Disassembled View....2847
Disassembly....2848
Inspection and Repair....2849
Reassembly....2849
Transfer Case Assembly....2851
Disassembled View....2851
Disassembly....2852
Inspection and Repair....2855
Reassembly....2858
Main Data and Specifications....2865
Special Tools....2868
Sec.5 BRAKES....2870
5A BRAKE CONTROL SYSTEM....2870
Service Precaution....2871
General Description....2872
Functional Description....2873
System Components....2879
Electronic Hydraulic Control Unit (EHCU)....2879
ABS Warning Light....2879
Wheel Speed Sensor....2879
G-Sensor....2879
Normal and Anti-lock Braking....2879
Brake Pedal Travel....2879
Acronyms and Abbreviations....2880
General Diagnosis....2880
General Information....2880
ABS Service Precautions....2880
Computer System Service Precautions....2880
General Service Precautions....2880
Note on Intermittents....2881
Test Driving ABS Complaint Vehicles....2881
"ABS" Warning Light....2881
Normal Operation....2881
Tech 2 Scan Tool....2882
DATA LIST....2885
ACTUATOR TEST....2886
Tech 2 Service Bleed....2890
Basic Diagnostic Flow Chart....2892
Basic Inspection Procedure....2892
EHCU Connector Pin-out Checks....2893
Circuit Diagram....2894
Connector List....2896
Part Location....2898
Symptom Diagnosis....2899
Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate....2899
Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)....2900
Chart A-2 Uneven Braking Occurs While ABS Works....2900
Chart TA-2 Uneven Braking Occurs While ABS Works (Use TECH 2)....2900
Chart A-3, TA-3 The Wheels Are Locked....2901
Chart A-4 Brake Pedal Feed Is Abnormal....2901
Chart A-5, TA-5 Braking Sound (From EHCU) Is Heard While Not Braking....2902
Diagnostic Trouble Codes....2903
Diagnosis By "ABS" Warning Light Illumination Pattern....2905
Diagnostic Trouble Codes (DTCs)....2906
Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated.....2908
Chart B-2 CPU Error (DTC 14 (Flash out) / C0271, C0272, C0273, C0284 (Serial communications))....2908
Chart B-3 Low or High Ignition Voltage (DTC 15 (Flash out) / C0277, 0278 (Serial communications))....2909
Chart B-4 Excessive Dump Time (DTC 17 (Flash out) / C0269 (Serial communications))....2909
Chart B-5 Excessive Isolation Time (DTC 18 (Flash out) / C0274 (Serial communications))....2909
Chart B-6 G-Sensor Output Failure (DTC 21 (Flash out) / C0276 (Serial communications))....2910
Chart B-7 Brake Switch Failure (DTC 22 (Flash out) / C0281 (Serial communications))....2910
Chart B-8 2WD Controller in 4WD Vehicle Controller (DTC 13 (Flash out) / C0285 (Serial communications)), 4WD State Input....2911
Chart B-9 Pump Motor Failure (DTC 32 (Flash out) / C0267, C0268 (Serial communications))....2911
Chart B-10 EHCU Valve Relay Failure (DTC 35 (Flash out) / C0265, C0266 (Serial communications))....2912
Chart B-11 FL Isolation Solenoid Coil Failure (DTC 41 (Flash out) / C0245, C0247 (Serial communications))....2912
Chart B-12 FL Dump Solenoid Coil Failure (DTC 42 (Flash out) / C0246, C0248 (Serial communications))....2912
Chart B-13 FR Isolation Solenoid Coil Failure (DTC 43 (Flash out) / C0241, C0243 (Serial communications))....2913
Chart B-14 FR Dump Solenoid Coil Failure (DTC 44(Flash out) / C0242, C0244 (Serial communications))....2913
Chart B-15 Rear Isolation Solenoid Coil Failure (DTC 45 (Flash out) / C0251, C0253 (Serial communications))....2913
Chart B-16 Rear Dump Solenoid Coil Failure (DTC 46 (Flash out) / C0252, C0254 (Serial communications))....2914
Chart B-17 FL Speed Sensor Open or Shorted (DTC 51 (Flash out) / C0225 (Serial communications))....2914
Chart B-18 FR Speed Sensor Open or Shorted (DTC 52 (Flash out) / C0221 (Serial communications))....2915
Chart B-19 Rear Speed Sensor Open or Shorted (DTC 53 (Flash out) / C0235 (Serial communications))....2916
Chart B-20 FL Speed Sensor Missing (DTC 61 (Flash out) / C0226, C0227 (Serial communications))....2917
Chart B-21 FR Speed Sensor Missing (DTC 62 (Flash out) / C0222, C0223 (Serial communications))....2918
Chart B-22 Rear Speed Sensor Missing (DTC 63 (Flash out) / C0236, C0237 (Serial communications))....2919
Chart B-23 Simultaneous Drop-out of Front Speed Sensor Signal (DTC 64 (Flash out) / C0229 (Serial communications))....2920
Chart B-24 Wheel Speed Input Abnormality (DTC 65 (Flash out) / C0238 (Serial communications))....2921
Unit Inspection Procedure....2922
Chart C-1-1 FL Sensor Output Inspection Procedure....2922
Chart C-1-2 FR Sensor Output Inspection Procedure....2923
Chart C-1-3 Rear Sensor Output Inspection Procedure....2924
Chart TC-1 Sensor Output Inspection Procedure....2924
Special Tools....2925
5B ANTI-LOCK BRAKE SYSTEM....2926
Service Precaution....2926
Electronic Hydraulic Control Unit....2927
Electronic Hydraulic Control Unit and Associated Parts....2927
Removal....2927
Disassembled View....2928
Disassembly....2928
Reassembly....2928
Installation....2928
Front Wheel Speed Sensor....2929
Front Wheel Speed Sensor and Associated Parts....2929
Removal....2929
Inspection and Repair....2929
Installation....2929
Rear Wheel Speed Sensor....2930
Removal....2930
Inspection and Repair....2930
Installation....2930
5C POWER-ASSISTED BRAKE SYSTEM....2931
Service Precaution....2932
General Description....2932
Diagnosis....2935
General Diagnosis....2936
Hydraulic Brakes....2939
Filling Master Cylinder Reservoir....2939
Deterioration of Brake Fluid....2939
Leakage of Brake Fluid....2939
Bleeding Brake Hydraulic System....2939
Flushing Brake Hydraulic System....2940
Brake Pipes and Hoses....2940
Brake Hose Inspection....2940
Front Caliper Brake Hose....2941
Front Caliper Brake Hose and Associated Parts....2941
Removal....2941
Installation....2941
Rear Axle Brake Hose....2942
Rear Axle Brake Hose and Associated Parts....2942
Removal....2942
Installation....2942
Brake Pipe....2943
Removal....2943
Installation....2943
P & B (Proportioning and Bypass) Valve....2944
P & B (Proportioning and Bypass) Valve Sectional View....2944
Removal....2944
Installation....2944
Main Data and Specifications....2945
Brake Pedal....2946
Checking Pedal Height....2946
Checking Pedal Travel....2946
Brake Pedal and Associated Parts....2947
Removal....2947
Installation....2947
Stoplight Switch....2948
Parts Location....2948
Removal....2948
Installation....2948
Main Data and Specifications....2949
Fluid Reservoir Tank....2950
Fluid Reservoir Tank and Associated Parts....2950
Removal....2950
Installation....2950
Master Cylinder Assembly....2951
Master Cylinder Assembly and Associated Parts....2951
Removal....2951
Inspection and Repair....2951
Installation....2953
Main Data and Specifications....2953
Special Tools....2953
Vacuum Booster Assembly....2954
Vacuum Booster Assembly and Associated Parts....2954
Removal....2954
Inspection and Repair....2954
Installation....2955
Exterior Components....2957
Exterior Components and Associated Parts....2957
Removal....2957
Inspection and Repair....2958
Installation....2958
Vacuum Booster Overhaul....2958
Vacuum Booster....2958
Main Data and Specifications....2959
Special Tools....2960
Front Disc Brake Pads....2961
Front Disc Brake Pads Inspection....2961
Front Disc Brake Pads and Associated Parts....2961
Removal....2962
Installation....2962
Front Disc Brake Rotor....2964
Inspection....2964
Replacing Brake Rotors....2964
Refinishing Brake Rotors....2964
Front Disc Brake Caliper Assembly....2966
Front Disc Brake Caliper Assembly and Associated Parts....2966
Removal....2966
Installation....2967
Front Disc Brake Caliper....2969
Front Disc Brake Caliper Disassembled View....2969
Disassembly....2969
Inspection and Repair....2970
Reassembly....2970
Main Data and Specifications....2972
Rear Disc Brake Pads....2973
Brake Pads Inspection....2973
Brake Pads and Associated Parts....2973
Removal....2974
Installation....2974
Rear Disc Brake Rotor....2976
Inspection....2976
Replacing Brake Rotors....2976
Refinishing Brake Rotors....2976
Rear Drum (In Disc) Inside Diameter Check....2977
Rear Disc Brake Caliper Assembly....2978
Rear Disc Brake Caliper Assembly and Associated Parts....2978
Removal....2978
Installation....2979
Rear Disc Brake Caliper....2981
Rear Disc Brake Caliper Disassembled View....2981
Disassembly....2981
Inspection and Repair....2982
Reassembly....2982
Main Data and Specifications....2984
5D PARKING BRAKE SYSTEM....2985
Service Precaution....2985
General Description....2985
Operation....2986
Parking Brake Lever and Front Cable....2987
Parking Brake Lever Assembly and Associated Parts....2987
Removal....2987
Installation....2987
Parking Brake Rear Cable....2988
Parking Brake Rear Cable and Associated Parts....2988
Removal....2989
Installation....2989
Inspection and Repair....2990
Parking Brake Adjustment....2990
Main Data and Specifications....2991
Sec.6 ENGINE....2992
X22SE 2.2L ENGINE....2992
6A ENGINE MECHANICAL....2992
Service Precaution....2993
General Description....2993
Engine Diagnosis....2995
Cylinder Head Cover....3008
Removal....3008
Installation....3009
Exhaust Manifold....3010
Removal....3010
Installation....3010
Crankshaft Pulley....3011
Removal....3011
Installation....3011
Intake Manifold....3012
Removal....3012
Installation....3013
Cylinder Head Assembly....3015
Removal....3015
Installation....3017
Timing Belt....3023
Removal....3023
Installation....3024
Camshaft....3027
Removal....3027
Installation....3028
Engine Assembly....3030
Engine and Associated Parts....3030
Removal....3030
Installation....3032
Cylinder Head....3034
Cylinder Head and Associated Parts....3034
Disassembly....3034
Inspection and Repair....3035
Reassembly....3036
Valve Spring, Valve, Valve Guide....3037
Valve Spring, Valve, Valve Guide and Associated Parts....3037
Disassembly....3038
Inspection and Repair....3038
Reassembly....3039
Camshaft....3040
Camshaft and Associated Parts....3040
Disassembly....3040
Reassembly....3041
Crankshaft....3042
Crankshaft and Associated Parts....3042
Disassembly....3042
Inspection and Repair....3043
Reassembly....3045
Piston and Connecting Rod....3048
Piston, Connecting Rod and Associate Parts....3048
Disassembly....3048
Inspection and Repair....3049
Reassembly....3051
Cylinder Block....3052
Cylinder Block and Associated Parts....3052
Disassembly....3053
Inspection and Repair....3053
Reassembly....3054
Cylinder Head Cover....3055
Cylinder Head Cover and Associated parts....3055
Removal....3056
Installation....3056
Balance Unit Assembly....3058
Balance Unit Assembly Associated Parts....3058
Disassembly....3059
Adjustment....3059
Reassembly....3061
Main Data and Specifications....3063
Special Tools....3068
6B ENGINE COOLING....3070
Service Precaution....3070
General Description....3071
Diagnosis....3073
Draining and Refilling Cooling System....3073
Water Pump....3074
Water Pump and Associated Parts....3074
Removal....3074
Inspection....3074
Installation....3074
Thermostat....3075
Removal....3075
Inspection....3075
Installation....3075
Radiator....3076
Radiator and Associated Parts....3076
Removal....3076
Inspection....3077
Installation....3077
Main Data and Specifications....3079
Special Tool....3079
6C ENGINE FUEL....3080
Service Precaution....3080
General Description....3081
Fuel Metering....3082
Fuel Filter....3083
Fuel Filter and Associated Parts....3083
Removal....3083
Inspection....3083
Installation....3083
Inspection....3084
In-Tank Fuel Filter....3084
Fuel Pump Flow Test....3084
Fuel Pump....3085
Fuel Pump and Associated Parts....3085
Removal....3085
Installation....3086
Fuel Tube / Quick - Connector Fittings....3087
Precautions....3087
Cautions During Work....3087
Removal....3087
Reuse of Quick-Connector....3088
Assembling Advice....3088
Fuel Pump Relay....3089
General Description....3089
Fuel Tank....3089
Fuel Tank and Associated Parts....3089
Removal....3090
Installation....3090
Fuel Gage Unit....3090
Removal and Installation....3090
Fuel Filler Cap....3091
General Description....3091
Inspection....3091
Main Data and Specifications....3092
Special Tool....3092
6D1 ENGINE ELECTRICAL....3093
Service Precaution....3093
Battery....3094
General Description....3094
Diagnosis....3094
Battery Charging....3095
Jump Starting....3095
Battery Removal....3096
Battery Installation....3096
Main Data and Specifications....3097
6D2 IGNITION SYSTEM....3098
Service Precaution....3098
General Description....3098
Diagnosis....3098
Ignition Module....3099
Removal....3099
Installation....3099
Spark Plug....3099
Removal....3099
Inspection and Repair....3099
Installation....3100
Crankshaft Angle Sensor....3101
Removal....3101
Installation....3101
Main Data and Specifications....3102
6D3 STARTING AND CHARGING SYSTEM....3103
Service Precaution....3103
Starting System....3104
General Description....3104
Diagnosis....3104
Starter....3105
Removal....3105
Installation....3105
Disassembled View....3106
Inspection and Repair....3107
Characteristic Test....3108
Charging System....3109
General Description....3109
General On-Vehicle Inspection....3109
Generator....3111
Removal....3111
Inspection....3111
Installation....3112
Disassembly....3112
Inspection and Repair....3114
Reassembly....3116
Main Data and Specifications....3117
6E1 ENGINE DRIVEABILITY AND EMISSIONS....3118
SPECIFICATIONS....3123
TIGHTENING SPECIFICATIONS....3123
DIAGRAMS AND SCHEMATICS....3124
ECM WIRING DIAGRAM (1 of 10)....3124
ECM WIRING DIAGRAM (2 of 10)....3125
ECM WIRING DIAGRAM (3 of 10)....3126
ECM WIRING DIAGRAM (4 of 10)....3127
ECM WIRING DIAGRAM (5 of 10)....3128
ECM WIRING DIAGRAM (6 of 10)....3129
ECM WIRING DIAGRAM (7 of 10)....3130
ECM WIRING DIAGRAM (8 of 10)....3131
ECM WIRING DIAGRAM (9 of 10)....3132
ECM WIRING DIAGRAM (10 of 10)....3133
ECM PINOUTS....3134
ECM Pinout Table, 32‐Pin Red Connector-Row ”A”....3134
ECM Pinout Table, 32‐Pin Red Connector-Row ”B”....3135
ECM Pinout Table, 32‐Pin White Connector-Row ”C”....3136
ECM Pinout Table, 32‐Pin White Connector-Row ”D”....3137
ECM Pinout Table, 32‐Pin White Connector-Row ”E”....3138
ECM Pinout Table, 32‐Pin White Connector-Row ”F”....3139
COMPONENT LOCATOR....3140
Undercarriage Component Locator Table....3143
Fuse And Relay Panel (Underhood Electrical Center)....3143
DIAGNOSIS Strategy‐Based Diagnostics....3144
Strategy‐Based Diagnostics....3144
DTC Stored....3144
No DTC....3144
No Matching Symptom....3144
Intermittents....3144
No Trouble Found....3144
Verifying Vehicle Repair....3144
GENERAL SERVICE INFORMATION....3144
Non‐OEM Parts....3144
Environment....3145
Emissions Control Information Label....3145
Maintenance Schedule....3145
Visual/Physical Engine Compartment Inspection....3145
Basic Knowledge Of Tools Required....3145
SERIAL DATA COMMUNICATIONS....3145
Class II Serial Data Communications....3145
ON‐BOARD DIAGNOSTIC (OBD)....3145
On‐Board Diagnostic Tests....3145
Comprehensive Component Monitor Diagnostic Operation....3146
Common OBD Terms....3146
The Diagnostic Executive....3147
DTC Types....3148
Verifying Vehicle Repair....3149
Reading Diagnostic Trouble Codes Using A Tech 2 Scan Tool....3149
Tech 2 Features....3151
Getting Started....3151
Operating Procedure (Example)....3152
DTC Modes....3153
DTC Information Mode....3153
Miscellaneous Test....3154
Lamps Test....3154
Relays Test....3155
EVAP Test....3157
Idle Air Control System Test....3157
Fuel System Test....3159
EGR Control Test....3160
Injector Balance Test....3160
Plotting Snapshot Graph....3161
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)....3162
Flow Chart for Snapshot Replay (Plotting Graph)....3163
PRIMARY SYSTEM‐BASED DIAGNOSTICS....3164
Primary System‐Based Diagnostics....3164
Fuel Control Heated Oxygen Sensors....3164
HO2S Heater....3164
ON‐BOARD DIAGNOSTIC (OBD) SYSTEM CHECK....3165
Circuit Description....3165
Diagnostic Aids....3165
Test Description....3165
A/C CLUTCH CONTROL CIRCUIT DIAGNOSIS....3167
Circuit Description....3167
Diagnostic Aids....3167
A/C Clutch Diagnosis....3168
ELECTRONIC IGNITION SYSTEM DIAGNOSIS....3170
VISUAL CHECK OF THE EVAPORATIVE EMISSION CANISTER....3170
IDLE AIR CONTROL (IAC) VALVE....3170
ENGINE CONTROL MODULE (ECM) DIAGNOSIS....3170
MULTIPLE ECM INFORMATION SENSOR DTCs SET....3171
Circuit Description....3171
Diagnostic Aids....3171
EXHAUST GAS RECIRCULATION (EGR) DIAGNOSIS....3174
ENGINE Tech 2 DATA DEFINITIONS AND RANGES....3174
TYPICAL SCAN DATA VALUES....3176
Test Conditions....3176
2.2L L‐4 Engine....3176
NO MALFUNCTION INDICATOR LAMP (MIL)....3179
Circuit Description....3179
Diagnostic Aids....3179
Test Description....3179
MALFUNCTION INDICATOR LAMP (MIL) ON STEADY....3182
Circuit Description....3182
Diagnostic Aids....3182
Test Description....3182
ENGINE CRANKS BUT WILL NOT RUN....3184
Circuit Description....3186
Diagnostic Aids....3186
FUEL SYSTEM ELECTRICAL TEST....3190
Circuit Description....3190
Diagnostic Aids....3190
Test Description....3190
Fuel Pressure Relief Procedure....3191
Fuel Gauge Installation....3191
FUEL SYSTEM DIAGNOSIS....3193
Circuit Description....3193
Test Description....3193
Fuel Pressure Relief Procedure....3194
Fuel Gauge Installation....3194
IDLE AIR CONTROL (IAC) SYSTEM CHECK....3198
Circuit Description....3198
Diagnostic Aids....3198
EXHAUST GAS RECIRCULATION (EGR) SYSTEM CHECK....3200
Circuit Description....3200
Diagnostic Aids....3200
MANIFOLD ABSOLUTE PRESSURE (MAP) OUTPUT CHECK....3202
Circuit Description....3202
Test Description....3202
ECM DIAGNOSTIC TROUBLE CODES....3204
ECM Diagnostic Trouble Codes....3204
DIAGNOSTIC TROUBLE CODE (DTC) P0106 MANIFOLD ABSOLUTE PRESSURE (MAP) CIRCUIT/RANGE PERFORMANCE PROBLEM....3206
DIAGNOSTIC TROUBLE CODE (DTC) P0107 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT LOW INPUT....3209
DIAGNOSTIC TROUBLE CODE (DTC) P0108 MANIFOLD ABSOLUTE PRESSURE (MAP) CIRCUIT HIGH INPUT....3212
DIAGNOSTIC TROUBLE CODE (DTC) P0112 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT LOW INPUT....3215
DIAGNOSTIC TROUBLE CODE (DTC) P0113 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT HIGH INPUT....3218
DIAGNOSTIC TROUBLE CODE (DTC) P0117 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT LOW INPUT....3221
DIAGNOSTIC TROUBLE CODE (DTC) P0118 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT HIGH INPUT....3223
DIAGNOSTIC TROUBLE CODE (DTC) P0121 THROTTLE POSITION (TP) SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM....3226
DIAGNOSTIC TROUBLE CODE (DTC) P0122 THROTTLE POSITION (TP) SENSOR CIRCUITLOW INPUT....3229
DIAGNOSTIC TROUBLE CODE (DTC) P0123 THROTTLE POSITION (TP) SENSOR CIRCUIT HIGH INPUT....3232
DIAGNOSTIC TROUBLE CODE (DTC) P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)....3235
DIAGNOSTIC TROUBLE CODE (DTC) P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)....3238
DIAGNOSTIC TROUBLE CODE (DTC) P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1)....3241
DIAGNOSTIC TROUBLE CODE (DTC) P0135 O2 SENSOR HEATER CIRCUIT MALFUNCTION....3244
DIAGNOSTIC TROUBLE CODE (DTC) P0171 SYSTEM TOO LEAN (BANK 1)....3247
DIAGNOSTIC TROUBLE CODE (DTC) P0172 SYSTEM TOO RICH (BANK 1)....3251
DIAGNOSTIC TROUBLE CODE (DTC) P0201 INJECTOR CIRCUIT MALFUNCTION-CYLINDER 1....3255
DIAGNOSTIC TROUBLE CODE (DTC) P0202 INJECTOR CIRCUIT MALFUNCTION-CYLINDER 2....3258
DIAGNOSTIC TROUBLE CODE (DTC) P0203 INJECTOR CIRCUIT MALFUNCTION- CYLINDER 3....3261
DIAGNOSTIC TROUBLE CODE (DTC) P0204 INJECTOR CIRCUIT MALFUNCTION-CYLINDER 4....3264
DIAGNOSTIC TROUBLE CODE (DTC) P0325 KNOCK SENSOR (KS) CIRCUIT MALFUNCTION....3267
DIAGNOSTIC TROUBLE CODE (DTC) P0327 KNOCK SENSOR (KS) CIRCUIT LOW INPUT....3270
DIAGNOSTIC TROUBLE CODE (DTC) P0336 CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT RANGE/PERFORMANCE....3273
DIAGNOSTIC TROUBLE CODE (DTC) P0337 CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT LOW INPUT....3275
DIAGNOSTIC TROUBLE CODE (DTC) P0341 CAMSHAFT POSITION (CMP) SENSOR CIRCUIT RANGE/PERFORMANCE....3277
DIAGNOSTIC TROUBLE CODE (DTC) P0342 CAMSHAFT POSITION (CMP) SENSOR CIRCUIT LOW INPUT....3280
DIAGNOSTIC TROUBLE CODE (DTC) P0351 IGNITION COIL ”A” PRIMARY/SECONDARY CIRCUIT MALFUNCTION....3283
DIAGNOSTIC TROUBLE CODE (DTC) P0352 IGNITION COIL ”B” PRIMARY/SECONDARY CIRCUIT MALFUNCTION....3285
DIAGNOSTIC TROUBLE CODE (DTC) P0401 EXHAUST GAS RECIRCULATION (EGR) FLOW INSUFFICIENT DETECTED....3287
DIAGNOSTIC TROUBLE CODE (DTC) P0402 EXHAUST GAS RECIRCULATION (EGR) EXCESSIVE FLOW DETECTED....3290
DIAGNOSTIC TROUBLE CODE (DTC) P0404 EXHAUST GAS RECIRCULATION (EGR) CIRCUIT RANGE/PERFORMANCE....3292
DIAGNOSTIC TROUBLE CODE (DTC) P0405 EXHAUST GAS RECIRCULATION (EGR) SENSOR CIRCUIT LOW....3296
DIAGNOSTIC TROUBLE CODE (DTC) P0406 EXHAUST GAS RECIRCULATION (EGR) SENSOR CIRCUIT HIGH....3299
DIAGNOSTIC TROUBLE CODE (DTC) P0443 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT MALFUNCTION....3302
DIAGNOSTIC TROUBLE CODE (DTC) P0480 COOLING FAN 1 CONTROL CIRCUIT MALFUNCTION....3304
DIAGNOSTIC TROUBLE CODE (DTC) P0481 COOLING FAN 2 CONTROL CIRCUIT MALFUNCTION....3307
DIAGNOSTIC TROUBLE CODE (DTC) P0502 VEHICLE SPEED SENSOR (VSS) CIRCUIT LOW INPUT....3310
DIAGNOSTIC TROUBLE CODE (DTC) P0506 IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED....3312
DIAGNOSTIC TROUBLE CODE (DTC) P0507 IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED....3315
DIAGNOSTIC TROUBLE CODE (DTC) P0563 SYSTEM VOLTAGE HIGH....3318
DIAGNOSTIC TROUBLE CODE (DTC) P0601 INTERNAL CONTROL MODULE MEMORY CHECK SUM ERROR....3320
DIAGNOSTIC TROUBLE CODE (DTC) P1106 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE....3321
DIAGNOSTIC TROUBLE CODE (DTC) P1107 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE....3323
DIAGNOSTIC TROUBLE CODE (DTC) P1111 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE....3325
DIAGNOSTIC TROUBLE CODE (DTC) P1112 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE....3328
DIAGNOSTIC TROUBLE CODE (DTC) P1114 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE....3330
DIAGNOSTIC TROUBLE CODE (DTC) P1115 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE....3332
DIAGNOSTIC TROUBLE CODE (DTC) P1121 THROTTLE POSITION (TP) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE....3335
DIAGNOSTIC TROUBLE CODE (DTC) P1122 THROTTLE POSITION (TP) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE....3337
DIAGNOSTIC TROUBLE CODE (DTC) P1171 FUEL SYSTEM LEAN DURING ACCELERATION....3339
DIAGNOSTIC TROUBLE CODE (DTC) 1404 EXHAUST GAS RECIRCULATION (EGR) CLOSED VALVE....3342
DIAGNOSTIC TROUBLE CODE (DTC) P1625 ECM UNEXPECTED RESET....3345
DIAGNOSTIC TROUBLE CODE (DTC) P1627 PCM A/D CONVERSION MALFUNCTION....3347
DIAGNOSTIC TROUBLE CODE (DTC) P1635 5 VOLT REFERENCE VOLTAGE CIRCUIT MALFUNCTION....3349
DIAGNOSTIC TROUBLE CODE (DTC) P1640 ODM OUTPUT CIRCUIT FAULT....3351
SYMPTOM DIAGNOSIS....3354
DEFAULT MATRIX TABLE....3377
Camshaft Position (CMP) Sensor....3380
Crankshaft Position (CKP) Sensor....3381
EEPROM....3383
Engine Coolant Temperature (ECT) Sensor....3383
Heated Oxygen Sensor (HO2S)....3384
Intake Air Temperature (IAT) Sensor....3385
Manifold Absolute Pressure (MAP) Sensor....3386
Malfunction Indicator Lamp (MIL)....3386
Engine Control Module (ECM)....3387
Throttle Position (TP) Sensor....3389
Vehicle Speed Sensor (VSS)....3390
Air Filter....3391
Idle Air Control (IAC) Valve....3392
Intake Air Duct....3394
Knock Sensor....3395
Oil Pressure Switch....3396
FUEL METERING SYSTEM Ac-celerator Cable Assembly....3397
Accelerator Pedal Replacement....3399
Fuel Filler Cap....3399
Fuel Filler Cap....3399
Fuel Filter....3399
Fuel Injectors....3401
Fuel Pressure Regulator....3402
Fuel Pump Assembly....3404
Fuel Pump Relay....3406
Fuel Rail Assembly....3406
Fuel Tank....3408
Throttle body (TB)....3409
ELECTRONIC IGNITION SYSTEM Ignition Control Module (ICM)....3411
Ignition Coil....3412
Spark Plugs....3412
Spark Plug Cables....3414
Spark Plug Cables....3414
EMISSIONS Catalytic Converter....3414
Air Conditioning Relay....3414
Ignition Timing Adjustment....3415
EVAP Canister Hoses....3415
EVAP Canister....3415
Linear Exhaust Gas Recirculation (EGR) Valve....3415
Wiring and Connectors....3416
ECM Connectors And Terminals....3416
Connectors And Terminals....3417
Wire Harness Repair: Twisted Shielded Cable....3417
Twisted Leads....3418
Weather-Pack Connector....3419
Com‐Pack III....3420
Metri‐Pack....3420
GENERAL DESCRIPTION -ECM AND SENSORS....3421
58X Reference ECM Input....3421
A/C Request Signal....3421
Crankshaft Position (CKP) Sensor....3421
Camshaft Position (CMP) Sensor And Signal....3421
Engine Coolant Temperature (ECT) Sensor....3422
Electrically Erasable Programmable Read Only Memory (EEPROM)....3422
Fuel Control Heated Oxygen Sensor (PreCatalyst)....3422
Intake Air Temperature (IAT) Sensor....3423
Linear Exhaust Gas Recirculation (EGR) Control....3423
Manifold Absolute Pressure (MAP) Sensor....3423
Engine Control Module (ECM)....3424
ECM Function....3424
ECM Components....3424
ECM Voltage Description....3424
ECM Inputs/Outputs....3424
ECM Service Precautions....3425
Throttle Position (TP) Sensor....3425
Transmission Range Switch....3425
Vehicle Speed Sensor (VSS)....3425
Use of Circuit Testing Tools....3425
Aftermarket Electrical And Vacuum Equipment....3426
Electrostatic Discharge Damage....3426
GENERAL DESCRIPTION-AIR INDUCTION....3426
Air Induction System....3426
GENERAL DESCRIPTION-FUEL METERING....3427
Acceleration Mode....3427
Accelerator Controls....3427
Battery Voltage Correction Mode....3427
CMP Signal....3427
Clear Flood Mode....3427
Deceleration Fuel Cutoff (DFCO) Mode....3427
Engine Speed/Vehicle Speed/ Fuel Disable Mode....3427
Fuel Cutoff Mode....3427
Fuel Injector....3427
Fuel Metering System Components....3427
Fuel Metering System Purpose....3428
Fuel Pressure Regulator....3428
Fuel Pump Electrical Circuit....3428
Fuel Rail....3428
Idle Air Control (IAC) Valve....3429
Run Mode....3429
Starting Mode....3429
Throttle Body Unit....3429
GENERAL DESCRIPTION-ELECTRONIC IGNITION SYSTEM....3430
Camshaft Position (CMP) Sensor....3430
Crankshaft Position (CKP) Sensor....3430
Electronic Ignition....3430
Ignition Coils....3430
Ignition Control....3430
Ignition Control Module (ICM)....3431
Ignition Control ECM Output....3431
Engine Control Module (ECM)....3431
Spark Plug....3432
A/C CLUTCH DIAGNOSIS....3433
A/C Clutch Circuit Operation....3433
A/C Clutch Circuit Purpose....3433
A/C Request Signal....3433
GENERAL DESCRIPTION-EVAPORATIVE EMISSION (EVAP) SYSTEM....3433
EVAP Emission Control System Purpose....3433
EVAP Emission Control System Operation....3434
GENERAL DESCRIPTION-EXHAUST GAS RECIRCULATION (EGR) SYSTEM....3434
EGR Purpose....3434
Linear EGR Valve....3434
Linear EGR Control....3434
Linear EGR Valve Operation And Results Of Incorrect Operation....3434
EGR Pintle Position Sensor....3434
GENERAL DESCRIPTION-POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM....3435
Crankcase Ventilation System Purpose....3435
SPECIAL TOOLS....3436
6F ENGINE EXHAUST....3437
Service Precaution....3437
General Description....3438
Front Exhaust Pipe....3439
Front Exhaust Pipe and Associated Parts....3439
Removal....3439
Installation....3439
Exhaust Silencer....3440
Exhaust Silencer and Associated Parts....3440
Removal....3440
Installation....3440
Rear Exhaust pipe....3441
Rear Exhaust pipe and Associated Parts....3441
Removal....3441
Installation....3441
Main Data and Specifications....3442
6G ENGINE LUBRICATION....3443
Service Precaution....3443
General Description....3444
Oil Pump....3445
Oil Pump and Associated Parts....3445
Disassembly....3446
Inspection and Repair....3446
Reassembly....3446
6H ENGINE SPEED CONTROL SYSTEM....3447
Service Precaution....3447
Accelerator Pedal Control Cable....3448
Removal....3448
Inspection....3448
Installation....3448
Adjustment....3448
Accelerator Pedal....3449
Accelerator Pedal and Associated Parts....3449
Removal....3449
Installation....3449
Adjustment....3449
6J INDUCTION....3450
Service Precaution....3450
Air Cleaner Filter....3451
Removal....3451
Inspection....3451
Installation....3451
6VD1 3.2L ENGINE....3452
6A ENGINE MECHANICAL....3452
Service Precaution....3453
General Description....3454
Engine Diagnosis....3455
Drive Belt (Serpentine Belt)....3470
Removal....3470
Inspection and Repair....3472
Installation....3473
Cylinder Head Cover LH....3474
Removal....3474
Installation....3475
Cylinder Head Cover RH....3476
Removal....3476
Installation....3477
Common Chamber....3478
Removal....3478
Installation....3479
Exhaust Manifold LH....3480
Removal....3480
Installation....3480
Exhaust Manifold RH....3481
Removal....3481
Installation....3482
Crankshaft Pulley....3483
Removal....3483
Installation....3483
Timing Belt....3484
Removal....3484
Installation....3485
Camshaft....3489
Removal....3489
Installation....3489
Cylinder Head....3493
Removal....3493
Installation....3493
Valve Stem Oil Controller , Valve Spring and Valve Guide....3495
Removal....3495
Installation....3495
Piston, Piston Ring and Connecting Rod....3496
Removal....3496
Installation....3497
Crankshaft and Main Bearings....3498
Removal....3498
Installation....3499
Rear Oil Seal....3503
Removal....3503
Installation....3503
Engine Assembly....3505
Removal....3505
Installation....3505
Cylinder Head....3508
Cylinder Head and Associated Parts....3508
Disassembly....3508
Clean....3509
Inspection and Repair....3509
Reassembly....3509
Valve Spring, Oil Controller, Valve, Valve Guide....3510
Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts....3510
Disassembly....3510
Inspection and Repair....3511
Reassembly....3514
Valve Clearance Adjustments....3515
Camshaft....3517
Camshaft and Associated Parts....3517
Disassembly....3517
Inspection and Repair....3518
Reassembly....3520
Crankshaft....3524
Crankshaft and Associated Parts....3524
Disassembly....3524
Inspection and Repair....3526
Inspection and Repair....3526
Reassembly....3528
Piston and Connecting Rod....3532
Piston, Connecting Rod and Associate Parts....3532
Disassembly....3532
Inspection and Repair....3533
Reassembly....3537
Cylinder Block....3540
Cylinder Block and Associated Parts....3540
Disassembly....3540
Inspection and Repair....3541
Reassembly....3542
Main Data and Specification....3545
Special Tool....3551
6B ENGINE COOLING....3553
Service Precaution....3553
General Description....3554
Diagnosis....3557
Draining and Refilling Cooling System....3558
Engine coolant change....3558
Water Pump....3559
Water Pump and Associated Parts....3559
Removal....3559
Inspection....3559
Installation....3559
Thermostat....3560
Thermostat and Associated Parts....3560
Removal....3560
Inspection....3560
Installation....3560
Radiator....3561
Radiator and Associated Parts....3561
Removal....3561
Inspection....3562
Installation....3563
Drive Belt and Cooling Fan....3564
Drive Belt and Associated Parts....3564
Inspection....3564
Installation....3564
Main Data and Specifications....3565
6C ENGINE FUEL....3566
Service Precaution....3566
General Description....3567
Fuel Filter....3569
Removal....3569
Inspection....3569
Installation....3569
Inspection....3569
In–Tank Fuel Filter....3569
Fuel Pump Flow Test....3570
Fuel Pump....3571
Fuel Pump and Associated Parts....3571
Removal....3571
Installation....3571
Fuel Tube / Quick ‐ Connector Fittings....3572
Precautions....3572
Cautions During Work....3572
Removal....3572
Fuel Pump Relay....3574
Fuel Tank....3575
Fuel Tank and Associated Parts....3575
Removal....3575
Installation....3576
Fuel Gauge Unit....3576
Fuel Filler Cap....3576
Inspection....3576
Main Data and Specifications....3577
6D1 ENGINE ELECTRICAL....3578
Service Precaution....3578
Battery....3579
General Description....3579
Diagnosis....3579
Battery Charging....3580
Jump Starting....3580
Battery Removal....3581
Battery Installation....3581
Main Data and Specifications....3582
6D2 IGNITION SYSTEM....3583
Service Precaution....3583
General Description....3584
Diagnosis....3584
Ignition Coil....3585
Removal....3585
Inspection and Repair....3585
Installation....3585
Spark Plug....3586
Inspection....3586
Replacement spark plugs....3586
Crankshaft Position Sensor....3587
Removal....3587
Installation....3587
Main Data and Specifications....3588
6D3 STARTING AND CHARGING SYSTEM....3589
Service Precaution....3589
Starting System....3590
General Description....3590
Diagnosis....3592
Starter....3593
Removal....3593
Installation....3593
Disassembled View....3594
Disassembly....3595
Inspection and Repair....3597
Reassembly....3601
Main Data and Specifications....3603
Charging System....3606
General Description....3606
General On–Vehicle Inspection....3606
Generator....3607
Removal....3607
Inspection....3607
Installation....3608
Disassembled View....3608
Disassembly....3609
Inspection and Repair....3610
Reassembly....3612
Bench Test....3613
Main Data and Specifications....3614
6E2 DRIVEABILITY AND EMISSIONS....3615
Specification....3619
Tightening Specifications....3619
Diagrams and Schematics....3620
PCM Wiring Diagram (1 of 8)....3620
PCM Wiring Diagram (2 of 8)....3621
PCM Wiring Diagram (3 of 8)....3622
PCM Wiring Diagram (4 of 8)....3623
PCM Wiring Diagram (5 of 8)....3624
PCM Wiring Diagram (6 of 8)....3625
PCM Wiring Diagram (7 of 8)....3626
PCM Wiring Diagram (8 of 8)....3627
.PCM Pinouts....3628
PCM Pinout Table, 32-Way Red Connector – Row “A”....3628
PCM Pinout Table, 32-Way Red Connector – Row “B”....3629
PCM Pinout Table, 32-Way White Connector – Row “C”....3630
PCM Pinout Table, 32-Way White Connector – Row “D”....3631
PCM Pinout Table, 32-Way Blue Connector – Row “E”....3632
PCM Pinout Table, 32-Way Blue Connector – Row “F”....3633
Component Locators....3634
Engine Component Locator....3634
Undercarriage Component Locator....3635
Undercarriage Component Locator Table....3635
Sensors and Miscellaneous Component Locators....3636
Fuse and Relay Panel (Underhood Electrical Center)....3638
Diagnosis....3639
Strategy-Based Diagnostics....3639
Strategy-Based Diagnostics....3639
DTC Stored....3639
No DTC....3639
No Matching Symptom....3639
Intermittents....3639
No Trouble Found....3639
Verifying Vehicle Repair....3639
General Service Information....3639
Non-OEM Parts....3639
Environment....3640
Emissions Control Information Label....3640
Maitenance Schedule....3640
Visual/Physical Engine Compartment Inspection....3640
Basic Knowledge of Tools Required....3640
Seral Data Communications....3640
Class II Serial Data Communications....3640
On-Board Diagnostic (OBD)....3640
On-Board Diagnostic Tests....3640
Comprehensive Component Monitor Diagnostic Operation....3641
Common OBD Terms....3641
The Diagnostic Executive....3642
DTC Types....3643
Verifying Vehicle Repair....3644
Reading Diagnostic Trouble Codes Using the TECH 2 Scan Tool....3644
Tech 2....3645
Tech 2 Features....3645
Getting Started....3646
Operating Procedure (For Example)....3646
DTC Modes....3647
DTC Information Mode....3648
Miscellaneous Test....3648
Lamps Test....3649
Relays Test....3649
EVAP Test....3651
Idle Air Control System Test....3651
Fuel System Test....3653
EGR Control Test....3654
Variable Intake Manifold Solenoid Test....3655
Injector Balance Test....3655
Plotting Snapshot Graph....3656
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)....3657
Flow Chart for Snapshot Replay (Plotting Graph)....3658
Primary System-Based Diagnostics....3659
Primary System-Based Diagnostics....3659
Fuel Control Heated Oxygen Sensors....3659
HO2S Heater....3659
On-Board Diagnostic (OBD) System Check....3660
Circuit Description....3660
Diagnostic Aids....3660
A/C Clutch Control Circuit Diagnosis....3662
Circuit Description....3663
Diagnostic Aids....3663
A/C Clutch Diagnosis....3663
Electronic Ignition System Diagnosis....3668
Visual Check of The Evaporative Emission Canister....3668
Fuel Metering System Check....3668
Idle Air Control (IAC) Valve....3668
Knock Sensor Diagnosis....3668
Powertrain Control Module (PCM) Diagnosis....3668
Multiple PCM Information Sensor DTCS Set....3668
Exhaust Gas Recirculation (EGR) Diagnosis....3672
Engine Tech 2 Data Definitions and Ranges....3672
Typical Scan Data Values....3674
No Malfunction Indicator Lamp (MIL)....3679
Malfunction Indicator Lamp (MIL) “ON” Steady....3682
Engine Cranks But Will Not Run....3685
Fuel System Diagnosis....3693
Idle Air Control (IAC) System Check....3698
Knock Sensor (KS) System Check....3700
Exhaust Gas Recirculation (EGR) System Check....3702
Manifold Absolute Pressure (MAP) Output Check....3704
Evaporative (EVAP) Emissions Canister Purge Valve Check....3706
PCM Diagnostic Trouble Codes....3709
Diagnostic Trouble Code (DTC) P0101 MAF System Performance....3712
Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency....3715
Diagnostic Trouble Code (DTC) P0103 MAF Sensor Circuit High Frequency....3718
Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage....3720
Diagnostic Trouble Code (DTC) P0108 MAP Sensor Circuit Hight Voltage....3723
Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage....3726
Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage....3729
Diagnostic Trouble Code (DTC) P0117 ECT Sensor Circuit Low Voltage....3733
Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage....3735
Diagnostic Trouble Code (DTC) P0121 TP System Performance....3738
Diagnostic Trouble Code (DTC) P0122 TP Sensor Circuit Low Voltage....3741
Diagnostic Trouble Code (DTC) P0123 TP Sensor Circuit High Voltage....3744
Diagnostic Trouble Code (DTC) P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1....3747
Diagnostic Trouble Code (DTC) P0132 HO2S Circuit High Voltage Bank 1 Sensor 1....3750
Diagnostic Trouble Code (DTC) P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1....3753
Diagnostic Trouble Code (DTC) P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1....3756
Diagnostic Trouble Code (DTC) P0152 HO2S Circuit High Voltage Bank 2 Sensor 1....3759
Diagnostic Trouble Code (DTC) P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1....3762
Diagnostic Trouble Code (DTC) P0171 Fuel Trim System Too Lean Bank 1....3765
Diagnostic Trouble Code (DTC) P0172 Fuel Trim System Rich Bank 1....3769
Diagnostic Trouble Code (DTC) P0174 Fuel Trim System Lean Bank 2....3773
Diagnostic Trouble Code (DTC) P0175 Fuel Trim System Rich Bank 2....3777
Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit....3781
Diagnostic Trouble Code (DTC) P0202 Injector 2 Control Circuit....3784
Diagnostic Trouble Code (DTC) P0203 Injector 3 Control Circuit....3787
Diagnostic Trouble Code (DTC) P0204 Injector 4 Control Circuit....3790
Diagnostic Trouble Code (DTC) P0205 Injector 5 Control Circuit....3793
Diagnostic Trouble Code (DTC) P0206 Injector 6 Control Circuit....3796
Diagnostic Trouble Code (DTC) P0325 KS Module Circuit....3799
Diagnostic Trouble Code (DTC) P0327 KS Sensor Circuit....3801
Diagnostic Trouble Code (DTC) P0336 58X Reference Signal Circuit....3804
Diagnostic Trouble Code (DTC) P0337 CKP Sensor Circuit Low Frequency....3806
Diagnostic Trouble Code (DTC) P0341 CMP Sensor Circuit Performamce....3809
Diagnostic Trouble Code (DTC) P0342 CMP Sensor Circuit Low....3812
Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit....3816
Diagnostic Trouble Code (DTC) P0352 Ignition 2 Control Circuit....3819
Diagnostic Trouble Code (DTC) P0353 Ignition 3 Control Circuit....3822
Diagnostic Trouble Code (DTC) P0354 Ignition 4 Control Circuit....3825
Diagnostic Trouble Code (DTC) P0355 Ignition 5 Control Circuit....3828
Diagnostic Trouble Code (DTC) P0356 Ignition 6 Control Circuit....3831
Diagnostic Trouble Code (DTC) P0404 EGR Open Stuck....3834
Diagnostic Trouble Code (DTC) P0405 EGR Low Voltage....3836
Diagnostic Trouble Code (DTC) P0406 EGR High Voltage....3839
Diagnostic Trouble Code (DTC) P0502 VSS Circuit Low Input....3842
Diagnositc Troule Code (DTC) P0562 System Voltage Low....3845
DTC P0563 – System Voltage High ....3847
DTC P0601 – PCM Memory ....3848
Diagnostic Trouble Code (DTC) P1171 Fuel System Lean Dueing Acceleration....3849
Diagnostic Trouble Code (DTC) P1380 ABS Rough Road ABS System Fault....3852
Diagnostic Trouble Code (DTC) P1381 ABS Rough Road Class 2 Serial Link Error....3853
Diagnostic Trouble Code (DTC) P1404 EGR Stuck Closed....3854
Diagnostic Trouble Code (DTC) P1508 IAC System Low RPM....3856
Diagnostic Trouble Code (DTC) P1509 IAC System High RPM....3859
Diagnostic Trouble Code (DTC) P1625 PCM Unexpected Reset....3862
Diagnostic Trouble Code (DTC) P1640 Output Driver Module (ODM) “A” Fault....3863
Symptom Diagnosis....3865
Default Matrix Table....3890
On-Vehicle Service Camshaft Position (CMP) Sensor....3893
Crankshaft Position (CKP) Sensor....3894
Engine Coolant Temperature (ECT) Sensor....3894
Heated Oxygen Sensor (HO2S)....3895
Intake Air Temperature (IAT) Sensor....3897
Knock Sensor (KS)....3898
Mass Air Flow (MAF) Sensor....3899
Manifold Absolute Pressure (MAP) Sensor....3899
Malfunction Indicator Lamp (MIL)....3900
Powertrain Control Module (PCM)....3900
EEPROM....3902
Throttle Position (TP) Sensor....3902
Vehicle Speed Sensor (VSS)....3902
Air Cleaner/Air Filter....3904
Idle Air Control (IAC) Valve....3905
Common Chamber....3906
Accelerator Cable Assembly....3906
Accelerator Pedal Replacement....3909
Fuel Fillter Cap....3911
Fuel Filter....3911
Fuel Gauge Unit....3914
Fuel Injectors....3914
Fuel Pressure Regulator....3915
Fuel Metering System....3917
Fuel Pump Assembly....3917
Fuel Pump Relay....3918
Fuel Rail Assembly....3918
Fuel Tank....3919
Throttle Body (TB)....3919
Electronic Ignition System....3921
Catalytic Converter....3922
Air Conditioning Relay....3922
EVAP Canister Hoses....3922
EVAP Canister....3922
EVAP Canister Purge Solenoid....3924
Fuel Tank Vent Valve....3925
Linear Exhaust Gas Recircula-tion (EGR) Valve....3925
Positive Crankcase Ventilation (PCV) Valve....3926
Wiring and Connectors....3927
PCM Connectors and Terminals....3927
Wire Harness Repair: Twisted Shielded Cable....3927
Twisted Leads....3928
Weather-Pack Connector....3929
Com-Pack III....3931
Metri-Pack....3931
General Description (PCM and Sensors)....3932
58X Reference PCM Input....3932
A/C Request Signal....3932
Crankshaft Position (CKP) Sensor....3932
Camshaft Position (CMP) Sensor and Signal....3932
Engine Coolant Temperature (ECT) Sensor....3932
Electrically Erasable Programmable Read Only Memory (EEPROM)....3932
Fuel Control Heated Oxygen Sensors....3932
Intake Air Temperature (IAT) Sensor....3933
Knock Sensor....3933
Linear Exhaust Gas Recirculation (EGR) Control....3934
Mass Air Flow (MAF) Sensor....3934
Manifold Absolute Pressure (MAP) Sensor....3934
Powertrain Control Module (PCM)....3935
PCM Function....3935
PCM Components....3935
PCM Voltage Description....3935
PCM Input/Outputs....3935
PCM Service Precautions....3936
Throttle Position (TP) Sensor....3936
Transmission Fluid Temperature (TFT) Sensor....3936
Transmission Range Switch....3936
Vehicle Speed Sensor (VSS)....3936
Use of Circuit Testing Tools....3937
Aftermarket Electrical and Vacuum Equipment....3937
Electrostatic Discharge Damage....3937
General Description (Air Induction)....3937
Air Induction System....3937
General Description (Fuel Metering)....3938
Acceleration Mode....3938
Accelerator Controls....3938
Battery Voltage Correction Mode....3938
CMP Signal....3938
Clear Flood Mode....3938
Deceleration Mode....3938
Engine Speed/Vehicle Speed/Fuel Disable Mode....3938
Fuel Cutoff Mode....3938
Fuel Injector....3938
Fuel Metering System Components....3938
Fuel Metering System Purpose....3939
Fuel Pressure Regulator....3939
Fuel Pump Electrical Circuit....3939
Fuel Rail....3939
Idle Air Control (IAC) Valve....3940
Run Mode....3940
Starting Mode....3940
Throttle Body Unit....3940
General Description (Electronic Ignition System)....3941
Camshaft Position (CMP) Sensor....3941
Crankshaft Position (CKP) Sensor....3941
Electronic Ignition....3941
Ignition Coils....3941
Ignition Control....3941
Ignition Control PCM Output....3942
Knock Sensor (KS) PCM Input....3943
Powertrain Control Module (PCM)....3943
Spark Plug....3943
A/C Clutch Diagnosis....3945
A/C Clutch Circuit Operation....3945
A/C Clutch Circuit Purpose....3945
A/C Request Signal....3945
General Description (Evaporative (EVAP) Emission System) ....3945
EVAP Emission Control System Purpose....3945
EVAP Emission Control System Operation....3945
General Description (Exhaust Gas Recirculation (EGR) System)....3945
EGR Purpose....3945
Linear EGR Valve....3946
Linear EGR Control....3946
Linear EGR Valve Operation and Results of Incorrect Operation....3946
EGR Pintle Position Sensor....3946
General Description (Positive Crankcase Ventilation (PCV) System)....3946
Crankcase Ventilation System Purpose....3946
Crankcase Ventilation System Operation....3947
Special Tools....3948
6F ENGINE EXHAUST....3949
Service Precaution....3949
General Description....3950
Three Way Catalytic Converter RH and Forked Exhaust Pipe....3951
Three Way Catalytic Converter RH and Forked Exhaust Pipe and Associated Parts....3951
Removal....3951
Installation....3951
Three Way Catalytic Converter LH and Forked Exhaust Pipe....3952
Three Way Catalytic Converter LH and Forked Exhaust Pipe and Associated Parts....3952
Removal....3952
Installation....3952
Forked Exhaust Pipe....3953
Forked Exhaust Pipe and Associated Parts....3953
Removal....3953
Installation....3953
Exhaust Silencer....3954
Exhaust Silencer and Associated Parts....3954
Removal....3954
Installation....3954
Rear Exhaust pipe....3955
Rear Exhaust pipe and Associated Parts....3955
Removal....3955
Installation....3955
Main Data and Specifications....3956
6G ENGINE LUBRICATION....3957
Service Precaution....3957
General Description....3958
Oil Pump....3959
Oil Pump and Associated Parts....3959
Oil Pump and Associated Parts....3960
Inspection and Repair....3960
Reassembly....3961
Oil Pan and Crankcase....3963
Removal....3963
Installation....3963
Oil Pump....3966
Removal....3966
Installation....3966
Oil Pump Oil Seal....3968
Removal....3968
Installation....3968
Oil Filter....3969
Removal....3969
Installation....3969
Main Data and Specification....3970
Special Tool....3971
6H ENGINE SPEED CONTROL SYSTEM....3972
Service Precaution....3972
Accelerator Pedal Control Cable....3973
Removal....3973
Inspection....3973
Installation....3973
Accelerator Pedal....3974
Accelerator Pedal and Associated Parts....3974
Removal....3974
Installation....3974
6J INDUCTION....3975
Service Precaution....3975
Air Cleaner Element....3976
Removal....3976
Inspection....3976
Installation....3976
Sec.7 TRANSMISSION....3977
7A AUTOMATIC TRANSMISSION....3977
Service Precaution....3978
Construction....3979
Range Reference Chart....3980
Normal Operation of 2000 4L30‐E Transmission....3981
Diagnosis....3981
Driver Information....3981
General Diagnosis Procedure....3984
Preliminary Inspection Chart....3985
Checking Transmission Fluid Level and Condition....3986
Test Driving....3987
Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart....3988
Mechanical / Hydraulic Diagnosis Symptoms Index....3989
Stall Test....3998
Line Pressure Test....3999
Shift Speed Chart....4000
Lockup Speed Chart....4001
Changing Transmission Fluid....4002
Selector Lever....4002
Inspection....4002
Removal....4003
Installation....4004
Select Cable....4004
Removal....4004
Installation....4006
Shift Lock Cable....4008
Removal....4008
Installation....4009
Mode Switch....4010
Removal....4010
Installation....4010
Transmission (With Transfer Case)....4012
Transmission and Associated Parts....4012
Removal....4013
Installation....4017
Solenoid (Main Case Valve Body)....4021
Removal....4021
Installation....4021
Solenoid (Adapter Case Valve Body)....4022
Removal....4022
Installation....4022
Valve Body Assembly (Main Case)....4023
Removal....4023
Installation....4023
Valve Body Assembly (Adapter Case)....4024
Removal....4024
Installation....4024
Powertrain Control Module (PCM)....4025
Removal....4025
Installation....4025
Speed Sensor (Extension Housing)....4026
Removal....4026
Installation....4026
Transmission Oil Temperature Sensor (Adapter Case)....4027
Removal....4027
Installation....4027
Front Oil Seal (Converter Housing)....4028
Removal....4028
Installation....4028
Rear Oil Seal (Extension Housing)....4028
Removal....4028
Installation....4028
Transmission (4L30‐E)....4029
Disassembly....4029
Reassembly....4033
Converter Housing and Oil Pump Assembly....4043
Disassembled View....4043
Disassembly....4043
Inspection and Repair....4043
Reassembly....4043
Oil Pump....4044
Disassembled View....4044
Disassembly....4044
Inspection and Repair....4044
Reassembly....4044
Main Case Valve Body....4045
Disassembled View....4045
Disassembly....4046
Inspection and Repair....4046
Reassembly....4046
Adapter Case Valve Body....4047
Disassembled View....4047
Disassembly....4047
Inspection and Repair....4047
Reassembly....4047
Third Clutch and Sprag Unit....4048
Disassembled View....4048
Disassembly....4048
Inspection and Repair....4049
Reassembly....4049
Third Clutch....4049
Disassembled View....4049
Disassemble....4050
Inspection and Repair....4050
Reassembly....4050
Sprag Unit....4051
Disassembled View....4051
Disassembly....4051
Inspection and Repair....4051
Reassembly....4051
Second Clutch....4052
Disassembled View....4052
Disassembly....4052
Inspection and Repair....4053
Reassembly....4053
3‐4 Accumulator Piston....4054
Disassembled View....4054
Disassembly....4054
Inspection and Repair....4055
Reassembly....4055
Reverse Clutch Piston and Center Support....4056
Disassembled View....4056
Disassembly....4057
Inspection and Repair....4057
Reassembly....4057
Overrun Clutch and Turbine Shaft....4058
Disassembled View....4058
Disassembly....4059
Inspection and Repair....4059
Reassembly....4059
Main Data and Specification....4061
Special Tools....4065
4L30–E Parts List....4068
7A1 TRANSMISSION CONTROL SYSTEM....4076
Service Precaution....4077
General Description....4077
Electronic Control Diagram....4078
Powertrain Control Module (PCM)....4079
Control System Diagram....4080
Shift Control....4081
Band Apply Control....4081
Torque Converter Clutch Control....4081
Line Pressure Control....4081
On‐Board Diagnostic System....4081
Fail Safe Mechanism....4081
Torque Management Control....4081
ATF Warning Control....4081
Shift Mode Control....4082
Gear Shift Control....4083
Winter Drive Mode....4084
Backup Mode....4084
Functions of Input / Output Components....4085
Diagnosis....4086
Electronic Diagnosis....4086
Check Trans Indicator....4086
Diagnostic Check....4086
“Check Trans” Check....4087
Tech 2 OBD II Connection....4088
F0: Transmission Data....4092
F1: PC Solenoid Data....4093
Flashing Code....4094
OBD II Diagnostic Management System....4095
16 ‐ Terminal Data Link Connector (DLC)....4096
Malfunction Indicator Lamp (MIL)....4097
Types Of Diagnostic Trouble Codes (DTCs)....4097
Clear DTC....4097
DTC Check....4098
PCM Precaution....4098
Information On PCM....4098
Intermittent Conditions....4099
Transmission and PCM Identification....4100
Isuzu Frontera....4100
Diagnostic Trouble Code (DTC) Identification....4101
DTC P0218/Flashing Code 71 Transmission Fluid Over Temperature....4102
DTC P0560/Flashing Code 72 System Voltage Malfunction....4104
DTC P0705/Flashing Code 73 Transmission Range Switch (Mode Switch) Illegal Position....4107
DTC P0706/Flashing Code 74 Transmission Range Switch (Mode Switch) Performance....4110
DTC P0712/Flashing Code 75 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input....4113
DTC P0713/Flashing Code 76 Transmission Fluid Temperature (TFT) Sensor Circuit High Input....4116
DTC P0719/Flashing Code 77 TCC Brake Switch Circuit High (Stuck On)....4119
DTC P0722/Flashing Code 78 Transmission Output Speed Sensor (OSS) Low Input....4122
DTC P0723/Flashing Code 79 Transmission Output Speed Sensor (OSS) Intermittent....4125
DTC P0730/Flashing Code 81 Transmission Incorrect Gear Ratio....4128
DTC P0748/Flashing Code 82 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical....4131
DTC P0753/Flashing Code 83 Shift Solenoid A Electrical....4133
DTC P0758/Flashing Code 84 Shift Solenoid B Electrical....4136
DTC P1790/Flashing Code 85 ROM Transmission Side Bad Check Sum....4140
DTC P1792/Flashing Code 86 EEPROM Transmission Side Bad Check Sum....4141
DTC P1835/Flashing Code 87 Kickdown Switch Always On....4142
DTC P1850/Flashing Code 88 Brake Band Apply Solenoid Malfunction....4144
DTC P1860/Flashing Code 89 TCC Solenoid Electrical....4148
Circuit Diagram....4151
Parts Location....4153
Harness Connector Faces....4154
7B MANUAL TRANSMISSION....4156
Service Precaution....4156
General Description....4157
Diagnosis (MUA)....4159
Transmission (MUA)....4160
Disassembled View....4160
Removal....4160
Installation....4165
Transmission Case and Transfer Case....4170
Major Component (MUA)....4170
Disassembly....4171
Reassembly....4174
Intermediate Plate with Gear Assembly, Detent, Shift Arm, and Inter-lock Pin (MUA)....4180
Disassembled View....4180
Disassembly....4181
Inspection and Repair....4182
Reassembly....4183
Reverse Gear and 5th Gear (MUA)....4184
Disassembled View....4184
Disassembly....4185
Inspection and Repair....4187
Reassembly....4187
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft (MUA)....4193
Disassmebled View....4193
Disassembly....4194
Inspection and Repair....4195
Reassembly....4198
Main Data and Specifications....4204
Special Tools (MUA)....4208
7C CLUTCH....4210
Service Precaution....4210
General Description....4211
Diagnosis....4217
Clutch Assembly (X22SE, MUA)....4218
Clutch Assembly (X22SE, MUA) and Associated Parts....4218
Removal....4218
Inspection and Repair....4219
Installation....4222
Clutch Assembly (6VD1, MUA)....4224
Clutch Assembly (6VD1, MUA) and Associated Parts....4224
Removal....4224
Inspection and Repair....4226
Installation....4230
Clutch Control....4232
Parts Location View....4232
Removal....4233
Inspection and Repair....4233
Installation....4234
Master Cylinder....4236
Disassembly....4236
Inspection and Repair....4236
Reassembly....4236
Slave Cylinder....4237
Disassembled View....4237
Disassembly....4237
Inspection and Repair....4237
Reassembly....4238
Damper Cylinder....4239
Disassembled View....4239
Disassembly....4239
Inspection and Repair....4239
Reassembly....4239
Main Data and Specifications....4240
Special Tools....4242
Sec.8 BODY AND ACCESSORIES....4243
8A LIGHTING SYSTEM....4243
Service Precaution....4244
Headlight Bulb....4245
Removal....4245
Installation....4245
Headlight Assembly....4245
Removal....4245
Installation....4245
Headlight Adjustment....4246
Fog Light Bulb....4247
Removal....4247
Installation....4247
Fog Light Assembly....4248
Removal....4248
Installation....4248
Fog Light Adjustment....4248
Clearance Light Bulb....4248
Removal....4248
Installation....4248
Front Combination Light Assembly....4249
Removal....4249
Installation....4249
Taillight Bulb....4249
Removal....4249
Installation....4249
License Plate Light Bulb (Bumper Type)....4250
Removal....4250
Installation....4250
License Plate Light Bulb (Tailgate Type)....4250
Removal....4250
Installation....4250
Stoplight Bulb....4251
Removal....4251
Installtion....4251
High Mounted Stoplight Assembly (4Door Model)....4251
Removal....4251
Installation....4251
High Mounted Stoplight Bulb (4Door Model)....4252
Removal....4252
Installation....4252
High Mounted Stoplight Assembly (2Door Model)....4252
Removal....4252
Installation....4252
High Mounted Stoplight Bulb (2Door Model)....4253
Removal....4253
Installation....4253
Backup Light Bulb....4253
Removal....4253
Installation....4253
Front Turn Signal Light Bulb....4254
Removal....4254
Installation....4254
Side Turn Signal Light Bulb....4254
Removal....4254
Installation....4254
Rear Turn Signal Light Bulb....4255
Removal....4255
Installation....4255
Dome Light Bulb....4255
Removal....4255
Installation....4255
Courtesy Light Bulb....4256
Removal....4256
Installation....4256
Map Light Bulb....4256
Removal....4256
Installation....4256
Luggage Room Light Bulb (4Door Model)....4257
Removal....4257
Installation....4257
Luggage Room Light Bulb (2Door Model)....4257
Removal....4257
Installation....4257
HVAC Bezel Illumination Light Bulb....4258
Removal and Installation....4258
Shift Lever Illumination Light Bulb (A/T)....4258
Removal....4258
Installation....4258
Ashtray Illumination Bulb....4259
Removal....4259
Installation....4259
Starter Switch....4259
Removal and Installation....4259
Lighting Switch (Combination Switch)....4259
Removal and Installation....4259
Dimmer-Passing Switch (Combination Switch)....4259
Removal and Installation....4259
Door Switch....4260
Removal....4260
Installation....4260
Rear Defogger Switch....4260
Removal....4260
Installation....4260
Key Remind Switch (Starter Switch)....4261
Removal and Installation....4261
Hazard Warning Light Switch....4261
Removal....4261
Installation....4261
Stoplight Switch....4261
Removal and Installation....4261
4WD Switch....4262
Removal....4262
Installation....4262
Backup Light Switch (M/T)....4262
Removal....4262
Installation....4262
Turn Signal Light Switch (Combination Switch)....4262
Removal and Installation....4262
Light and Bulb Specifications (4Door Model ｷ Spear Tire Under Mount Type)....4263
Light and Bulb Specifications (4Door Model ｷ Spear Tire Tail....4264
Light and Bulb Specifications (2Door Model)....4265
8B WIPER / WASHER SYSTEM....4267
Service Precaution....4267
Windshield Wiper/Washer System....4268
General Description....4268
Windshield Wiper And Washer Switch....4268
Removal and Installation....4268
Windshield Wiper Motor....4268
Removal....4268
Installation....4268
Windshield Washer Motor....4269
Removal....4269
Installation....4269
Windshield Washer Spray Pattern....4270
Windshield Wiper Linkage....4271
Windshield Wiper Linkage and Associated Parts....4271
Removal....4271
Installation....4271
Windshield Wiper Arm/Blade....4272
Removal....4272
Installation....4272
Windshield Wiper Blade Rubber....4273
Removal....4273
Installation....4273
Rear Wiper/Washer System....4274
General Description....4274
Rear Wiper and Washer Switch....4274
Removal....4274
Installation....4274
Rear Wiper Motor (4Door Model)....4275
Removal....4275
Installation....4275
Rear Wiper Motor (2Door Model)....4276
Removal....4276
Installation....4276
Rear Washer Motor....4277
Removal....4277
Installation....4277
Alarm and Relay Control Unit....4277
Removal....4277
Installation....4277
Rear Wiper Arm/Blade (4Door Model)....4278
Removal....4278
Installation....4278
Rear Wiper Arm/Blade (2Door Model)....4278
Removal....4278
Installation....4278
Rear Washer Nozzle (4Door Model)....4279
Removal....4279
Installation....4279
Rear Washer Spray Pattern....4279
Rear Washer Nozzle (2Door Model)....4280
Removal....4280
Installation....4280
Rear Washer Spray Pattern....4280
Rear Wiper Blade Rubber....4281
Removal....4281
Installation....4281
Main Data and Specifications....4282
8C ENTERTAINMENT....4283
Service Precaution....4283
Cigarette Lighter....4284
General Description....4284
Removal....4284
Installation....4284
Digital Clock....4284
Removal....4284
Installation....4285
Rod Type Antenna....4285
Removal....4285
Installation....4285
Radio....4286
Removal....4286
Installation....4286
Speaker....4287
Front Speaker....4287
Tweeter Assembly....4287
Rear Speaker (4Door Model)....4287
Rear Speaker (2Door Model)....4288
Accessory Socket....4288
Front Accessory Socket....4288
Rear Accessory Socket....4288
Horn....4289
Removal....4289
Installation....4289
8D WIRING SYSTEM....4290
Service Precaution....4291
General Description....4292
Main Data and Specifications....4314
Fuse, Fusible Link and Circuit Breaker Location....4314
Relay & Fuse Box (Engine Room)....4315
Relay & Fuse Box (Instrument panel)....4315
Fuse Block Circuit ....4316
Reference Table of Fuse, Fusible Link and Circuit Breaker....4322
Relay Location....4324
Diode Location....4326
Grounding Point....4328
Cable Harness Routing....4332
Start and Charging....4335
General Description....4335
Circuit Diagram....4336
Parts Location....4338
Powertrain Control Module (PCM)....4339
General Description....4339
Circuit Diagram....4340
Parts Location....4353
Circuit Diagram....4356
Parts Location....4366
Headlight and Fog Light....4368
General Description....4368
Circuit Diagram....4369
Parts Location....4371
Diagnosis....4372
Clearance Light, Tail Light and License Plate Light....4376
General Description....4376
Circuit Diagram....4377
Parts Location....4379
Diagnosis....4380
Interior Illumination Light....4382
General Description....4382
Circuit Diagram....4383
Parts Location....4386
Diagnosis....4387
Turn Signal Light, Hazard Warning Light....4388
General Description....4388
Circuit Diagram....4389
Parts Location....4391
Diagnosis....4392
Stoplight....4394
General Description....4394
Circuit Diagram....4395
Parts Location (2Door Model)....4396
Diagnosis....4398
Backup Light....4400
General Description....4400
Circuit Diagram....4401
Parts Location....4402
Diagnosis....4403
Horn....4405
General Description....4405
Circuit Diagram....4406
Parts Location....4407
Diagnosis....4408
Dome Light, Luggage Room Light, Courtesy Light, Map Light, Seat Belt Switch and Warning Buzzer....4409
General Description....4409
Circuit Diagram....4410
Parts Location....4416
Diagnosis....4417
Power Door Lock....4418
General Description....4418
Circuit Diagram....4419
Parts Location....4422
Diagnosis....4423
Power Window....4425
General Description....4425
Circuit Diagram....4426
Parts Location....4427
Diagnosis....4428
Cruise Control....4433
General Description....4433
Circuit Diagram....4434
Parts Location....4436
Diagnosis....4437
Anti‐Lock Brake System (ABS)....4441
General Description....4441
Circuit Diagram....4442
Parts Location....4444
A/T Shift Lock....4445
General Description....4445
Circuit Diagram....4446
Parts Location....4447
Windshield Wiper and Washer....4448
General Description....4448
Circuit Diagram....4449
Parts Location....4452
Diagnosis....4453
Rear Wiper/Washer....4459
General Description....4459
Circuit Diagram....4460
Parts Location....4465
Diagnosis....4466
Rear Defogger/Mirror Defogger....4470
General Description....4470
Circuit Diagram....4471
Diagnosis....4476
Audio....4479
General Description....4479
Circuit Diagram....4480
Parts Location....4481
Cigarette Lighter, Digital Clock and Accessory Socket....4482
General Description....4482
Circuit Diagram....4483
Parts Location....4484
Diagnosis....4485
Power Door Mirror....4486
General Description....4486
Circuit Diagram....4487
Parts Location....4489
Diagnosis....4490
Keyless Entry....4492
General Description....4492
Circuit Diagram....4493
Parts Location....4497
Keyless Entry System....4498
Meter and Warning/Indicator Light....4499
General Description....4499
Circuit Diagram....4500
Parts Location....4507
Diagnosis....4508
A/T Shift Indicator....4513
General Description....4513
Circuit Diagram....4514
Parts Location....4516
Heater and Air Conditioning....4517
General Description....4517
Circuit Diagram....4518
Parts Location....4520
Heater and Air Conditioning....4521
General Description....4521
Circuit Diagram....4522
Parts Location....4528
Sunroof....4529
General Description....4529
Circuit Diagram....4530
Parts Location....4531
Diagnosis....4532
Supplemental Restraint System (SRS)-Air Bag....4533
General Description....4533
Circuit Diagram....4534
Parts Location....4535
Shift on the Fly System....4536
General Description....4536
Circuit Diagram....4538
Parts Location....4540
Harness Connector Faces....4541
8E METER AND GAUGE....4558
Service Precaution....4558
Meter Assembly....4559
General Description....4559
Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination Lights....4559
Table for Meter/Gauge Connector Terminal Connections....4563
Removal....4567
Installation....4567
Warning Light Bulb, Indicator Light Bulb, Illumination Light Bulb, A/T Shift Indicator Light Bulb....4567
Removal....4567
Installation....4567
Vehicle Speed Sensor....4568
Removal....4568
Installation....4568
Fuel Tank Unit....4568
Removal....4568
Installation....4568
Main Data and Specifications....4569
8F BODY STRUCTURE....4570
Service Precaution....4571
Frame....4571
General Description....4571
Frame Dimensions (LWB)....4572
Frame Dimensions (SWB)....4573
General Description (Bumper)....4574
Front Bumper....4574
Parts Location....4574
Removal....4575
Installation....4575
Front Bumper Slider Bracket....4576
Removal....4576
Installation....4576
Rear Bumper....4577
Parts Location....4577
Removal....4578
Installation....4578
Rear Bumper Slider....4579
Removal....4579
Installation....4579
General Description (Sheet Metal)....4580
Engine Hood....4580
Parts Location....4580
Removal....4581
Installation....4581
Engine Hood Lock....4583
Parts Location....4583
Removal....4583
Installation....4584
Radiator Grille....4585
Parts Location....4585
Removal....4585
Installation....4586
Front Fender Panel....4587
Parts Location....4587
Removal....4587
Installation....4588
Body Mounting....4590
Parts Location....4590
Tightening Torque....4590
Body Dimension....4591
Front Section....4591
Room Section (SWB)....4594
Room Section (LWB)....4596
Rear Section (SWB)....4598
Rear Section (LWB)....4600
Side Body Section (Front side)....4602
Side Body Section (Rear side)....4604
General Description (Body)....4606
Instrument Panel Assembly....4606
Parts Location....4606
Removal....4607
Installation....4609
Front Door Assembly....4610
Parts Location....4610
Removal....4610
Installation....4611
Rear Door Assembly....4612
Parts Location....4612
Removal....4612
Installation....4613
Front Window Regulator, Glass and Glass Run....4614
Parts Location....4614
Removal....4615
Installation....4616
Rear Window Regulator, Glass and Glass Run....4617
Parts Location....4617
Removal....4618
Installation....4619
Tailgate (LWB)....4620
Parts Location....4620
Removal....4621
Installation....4622
Tailgate (SWB)....4623
Parts Location....4623
Removal....4623
Installation....4624
Rear Hatchgate (LWB)....4625
Parts Location....4625
Removal....4626
Installation....4626
Adjustment....4628
Tailgate Glass (SWB)....4629
Parts Location....4629
Removal....4629
Installation....4630
Spare Tire Carrier....4631
Parts Location....4631
Removal....4631
Installation....4631
Windshield....4632
Parts Location....4632
Removal....4632
Installation....4633
Rear Quarter Glass (LWB)....4636
Parts Location....4636
Removal....4636
Installation....4637
Rear Quarter Glass (SWB)....4638
Parts Location....4638
Removal....4638
Installation....4638
Side Window Glass (SWB)....4640
Parts Location....4640
Removal....4640
Installation....4640
Main Data and Specifications....4642
Special Tools....4645
8G BODY AND ACCESSORIES....4646
Service Precaution....4646
Front Seat Assembly....4647
Front Seat Assembly and Associated Parts....4647
Removal....4647
Installation....4649
Rear Seat Assembly (LWB)....4650
Rear Seat Cushion Assembly and Associated Parts....4650
Removal....4650
Installation....4651
Rear Seat Back Assembly and Associated Parts....4652
Removal....4652
Installation....4653
Rear Seat Assembly (SWB)....4654
Rear Seat Assembly and Associated Parts....4654
Removal....4655
Installation....4655
Main Data and Specifications....4656
Torque Specifications....4656
8H SECURITY AND LOCKS....4658
Service Precaution....4658
Front Door Lock Assembly....4659
Front Door Lock Assembly and Associated Parts....4659
Removal....4660
Installation....4661
Front Outside Handle....4662
Front Outside Handle and Associated Parts....4662
Removal....4662
Installation....4662
Rear Door Lock Assembly....4663
Rear Door Lock Assembly and Associated Parts....4663
Removal....4664
Installation....4664
Rear Outside Handle....4665
Rear Outside Handle and Associated Parts....4665
Removal....4665
Installation....4665
Tailgate Lock and Hatchgate Lock (LWB)....4666
Tailgate Lock, Hatchgate Lock and Associated Parts....4666
Removal....4667
Installation....4668
Tailgate Lock (SWB)....4669
Tailgate Lock and Associated Parts....4669
Removal....4669
Installation....4670
Fuel Filler Door Lock....4671
Fuel Filler Door Lock and Associated Parts....4671
Removal....4671
Installation....4672
Key....4673
Key Coding....4673
Key Styles....4673
Power Door Lock System....4674
General Description....4674
Door Lock Key Switch....4674
Front Door Lock Actuator....4674
Rear Door Lock Actuator....4674
Tailgate Lock Actuator....4674
Fuel Filler Door Lock Actuator....4674
Keyless Entry System....4675
General Description....4675
Keyless Entry Control Unit....4675
Keyless Entry Control Unit/Transmitter Replacement....4675
Main Data and Specifications....4676
8I SUNROOF/CONVERTIBLE TOP....4677
Service Precaution....4677
Sunroof Glass (LWB)....4678
Sunroof Glass and Associated Parts....4678
Removal....4678
Installation....4679
Sunroof Glass (SWB)....4679
Sunroof Glass and Associated Parts....4679
Removal....4680
Installation....4680
Sunroof Deflector (LWB)....4681
Removal....4681
Installation....4681
Sunroof Deflector (SWB)....4682
Parts Location....4682
Removal....4682
Installation....4682
Sunshade (LWB)....4683
Disassembled View....4683
Removal....4683
Installation....4684
Sunroof Frame Complete Assembly (LWB)....4685
Sunroof Frame Complete Assembly and Associated Parts....4685
Removal....4685
Installation....4686
Sunroof Switch....4686
Removal....4686
Installation....4686
Sunroof Control Unit....4687
Removal....4687
Installation....4687
Safety Stop Switch....4687
Removal....4687
Installation....4687
Limit Switch....4688
Removal....4688
Installation....4688
Sunroof Motor....4688
Removal....4688
Installation....4688
Resin Top Assembly....4689
Resin Top Assembly and Associated Parts....4689
Removal....4689
Installation....4690
Seat Belt Cross Bar Assembly....4691
Seat Belt Cross Bar Assembly and Associated Parts....4691
Removal....4691
Installation....4692
Main Data and Specifications....4693
8J EXTERIOR / INTERIOR TRIM....4694
Service Precaution....4695
Consoles....4696
Consoles and Associated Parts....4696
Removal....4696
Installation....4696
Front Door Trim Panel....4697
Front Door Trim Panel and Associated Parts....4697
Removal....4698
Installation....4698
Rear Door Trim Panel....4699
Rear Door Trim Panel and Associated Parts....4699
Removal....4700
Installation....4700
Door Mirror Assembly....4701
Removal....4701
Installation....4701
Mirror Replacement....4701
Interior Trim Panels (LWB)....4703
Interior Trim Panels and Associated Parts....4703
Removal....4703
Installation....4705
Interior Trim Panels (SWB)....4706
Interior Trim Panels and Associated Parts....4706
Removal....4706
Installation....4707
Overhead Console....4708
Parts Location....4708
Removal....4708
Installation....4708
Headlining (LWB)....4709
Parts Location....4709
Removal....4709
Installation....4710
Headlining (SWB)....4711
Parts Location....4711
Removal....4712
Installation....4712
Wheel Arch Protector (LWB)....4713
Wheel Arch Protector and Associated Parts....4713
Removal....4713
Installation....4713
Wheel Arch Moulding (SWB)....4714
Wheel Arch Moulding and Associated Parts....4714
Removal....4714
Installation....4715
Wheel Arch Moulding (LWB)....4716
Wheel Arch Moulding and Associated Parts....4716
Removal....4716
Installation....4717
Fuel Filler Door....4718
Parts Location....4718
Removal....4718
Installation....4718
Roof Rail....4719
Parts Location....4719
Removal....4719
Installation....4719
Power Door Mirror System....4720
General Description....4720
Door Mirror Switch....4720
Power Window System....4721
General Description....4721
Power Window Switch Driver Seat Side....4721
Power Window Motor....4722
Main Data and Specifications....4724
Sec.9 RESTRAINTS....4725
9A SEAT BELT SYSTEM....4725
Service Precaution....4725
Front Seat Belt (LWB)....4726
Front Seat Belt and Associated Parts....4726
Removal....4726
Inspection....4726
Installation....4727
Front Seat Belt (SWB)....4728
Front Seat Belt and Associated Parts....4728
Removal....4728
Inspection....4729
Installation....4730
Rear Seat Belt (LWB)....4731
Rear Seat Belt and Associated Parts....4731
Removal....4731
Inspection....4732
Installation....4733
Rear Seat Belt (SWB)....4734
Rear Seat Belt and Associated Parts....4734
Removal....4734
Inspection....4735
Installation....4736
Front Seat Buckle Assembly....4737
Removal....4737
Installation....4737
Rear Center Seat Belt / Buckle Assembly....4738
Rear Center Seat Belt / Buckle Assembly and Associated Parts....4738
Removal....4738
Installation....4738
Child Seat Tether Anchor Bracket (Child Restraint)....4739
General Description....4739
Child Seat Tether Anchor Bracket and Associated Parts....4739
Installation....4739
Main Data and Specifications....4740
9J SUPPLEMENTAL RESTRAINT SYSTEM....4742
Service Precaution....4742
General Description....4743
SRS Component and Wiring Location View....4745
Component Description....4745
Definition....4748
Diagnosis....4749
SRS Connector Body Face Views....4750
On-Vehicle Service....4751
Air Bag Assembly Handling / Shipping / Scrapping....4752
Special Tools....4768
Service Precaution....4774
Sensing and Diagnostic Module (SDM)....4776
Service Precautions....4776
Removal....4776
Installation....4776
Driver Air Bag Assembly....4778
Service Precautions....4778
Removal....4778
Installation....4778
Steering Wheel....4779
Service Precautions....4779
Removal....4779
Installation....4780
SRS Coil Assembly....4781
Service Precaution....4781
Removal....4781
How to Disconnect the horn terminal....4783
How to Connect Horn Terminal....4783
Installation....4784
Steering Column....4786
Service Precaution....4786
Removal....4786
Installation....4788
Passenger Air Bag Assembly....4790
Service Precaution....4790
Removal....4790
Installation....4790
Main Data and Specifications....4791
SRS Air Bag System Inspection Standards For Repair....4792
9J1 SRS CONTROL SYSTEM....4793
Service Precaution....4793
Diagnostic Information....4794
Parts For Electrical Circuit Wiring....4796
System Schematic....4797
SRS Diagnostic System Check....4797
Chart A SDM Integrity Check....4801
Chart B "AIR BAG" Warning Lamp Comes "ON" Steady....4803
Chart C "AIR BAG" Warning Lamp Does Not Comes "ON" Steady....4805
DTC 15 Passenger Deployment Loop Resistance High....4808
DTC 16 Passenger Deployment Loop Resistance Low....4811
DTC 17 Passenger Deployment Loop Open....4814
DTC 18 Passenger Deployment Loop Short To Ground....4817
DTC 19 Passenger Deployment Loop Short To Voltage....4820
DTC 21 Driver Deployment Loop Resistance High....4823
DTC 22 Driver Deployment Loop Resistance Low....4826
DTC 24 Driver Deployment Loop Short To Ground....4829
DTC 25 Driver Deployment Loop Short To Voltage....4832
DTC 26 Driver Deployment Loop Open....4836
DTC 51 Deployment Event Commanded....4839
DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy Reserves Out Of Range....4841
DTC 61 Warning Lamp Circuit Failure....4844
DTC 71 Internal SDM Fault....4846
Sec.10 CONTROL SYSTEMS....4848
10A CRUISE CONTROL SYSTEM....4848
Service Precaution....4848
General Description....4849
Diagnosis....4849
Brake Switch....4850
Removal and Installation....4850
Adjustment....4850
Clutch Switch....4850
Removal and Installation....4850
Adjustment....4850
Cruise Control Unit....4851
Removal....4851
Installation....4851
Cruise Actuator....4852
Actuator Cable Diagram....4852
Removal....4852
Installation....4852
Adjustment....4853
Mode Switch....4853
Removal and Installation....4853
Cruise Control Main Switch....4853
Removal....4853
Installation....4853
Cruise Control Switch (Combination Switch)....4854
Removal and Installation....4854
2001 MODEL....2
(UE) FRONTERA....4855
Sec.0 GENERAL INFORMATION....4856
0A GENERAL INFORMATION....4856
General Repair Instruction....4856
Illustration Arrows....4857
Identification....4858
Lifting Instructions....4860
Standard Bolts Torque Specifications....4862
Abbreviations Charts....4863
Service Parts Identification Plate....4865
0B MAINTENANCE AND LUBRICATION....4866
Maintenance Schedule List....4866
Service and Maintenance....4867
Recommended Fluids and Lubricants....4874
Lubricant Viscosity Chart....4875
Recommended Liquid Gasket....4877
Recommended Thread Locking Agents....4878
Maintenance Service Data....4879
Sec.1 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)....4880
1A HVAC SYSTEMS....4880
Service Precaution....4882
Heating and Ventilation System....4882
General Description....4882
Heater and Ventilation Associated Parts....4883
Venti l ati on....4884
Circuit Diagram....4887
Diagnosis....4888
Condenser Fan Diagnosis....4892
Individual Inspection....4895
General Repair Procedure....4896
Heater Unit....4898
Heater Unit and Associated Parts....4898
Removal....4898
Installation....4899
Heater Core and / or Mode Door....4899
Disassembled View....4899
Removal....4899
Inspection....4900
Installation....4900
Heater Mode Control Link Unit....4901
Disassembled View....4901
Removal....4901
Installation....4902
Heater Temperature Control Link Unit....4902
Disassembled View....4902
Removal....4902
Installation....4903
Blower Assembly....4903
Blower Assembly and Associated Parts....4903
Removal....4903
Installation....4904
Blower Link Unit and / or Mode door....4904
Disassembled View....4904
Removal....4904
Installation....4905
Blower Motor....4906
Blower Motor and Associated Parts....4906
Removal....4906
Installation....4906
Rear Heater Duct, Defroster Nozzle and Ventilation Duct....4907
Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts....4907
Removal....4907
Installation....4908
Control Lever Assembly and / or Control Cable....4908
Control Lever Assembly, Control Cable and Associated Parts....4908
Removal....4909
Installation....4910
Control Panel Illumination Bulb....4911
Control Panel Illumination Bulb and Associated Parts....4911
Removal....4911
Installation....4911
Resistor....4911
Resistor and Associated Parts....4911
Removal....4911
Installation....4911
Air Conditioning System....4912
General Description....4912
Circuit Diagram....4918
Diagnosis....4920
Individual Inspection....4928
General Repair Procedure....4929
Leak Check....4931
Compressor Assembly....4936
Compressor Assembly and Associated Parts (6VD1)....4936
Removal....4936
Installation....4937
New Compressor Installation....4937
Condenser Assembly....4939
Condenser Assembly and Associated Parts....4939
Removal....4939
Installation....4939
Condenser Fan Motor....4940
Condenser Fan Motor and Associated Parts....4940
Removal....4940
Installation....4941
Receiver / Drier....4942
Receiver / Drier and Associated Parts....4942
Removal....4942
Installation....4942
Pressure Switch....4943
Pressure Switch and Associated Parts....4943
Removal....4943
Installation....4943
Evaporator Assembly....4944
Evaporator Assembly and Associated Parts....4944
Removal....4944
Installation....4945
Electronic Thermostat, Evaporator Core and/or Expansion Valve....4946
Disassembled View....4946
Removal....4946
Installation....4947
Refrigerant Line....4948
Refrigerant Line and Associated Parts....4948
Removal....4948
Installation....4949
Main Data And Specifications....4950
Compressor....4953
Service Precaution....4953
General Description....4953
Diagnosis....4954
Magnetic Clutch Assembly (DKV-14G Type)....4955
Parts Location View....4955
Removal....4955
Inspection and Repair....4957
Installation....4957
Compressor Oil....4959
Oil Specification....4959
Handling of Oil....4959
Compressor Oil Check....4959
Checking and Adjusting Oil Quantity for Used Compressor....4959
Checking and Adjusting for Compressor Replacement....4960
Contamination of Compressor Oil....4960
Oil Return Operation....4960
Replacement of Component Parts....4960
Main Data and Specifications....4961
Special Tools....4963
Automatic Air Conditioning System....4964
General Description....4964
Automatic Air Conditioner Parts Configuration....4964
Refrigerant Line and Associated Parts....4965
Circuit Diagram....4966
Functions and Features....4971
Automatic Air Conditioner Block Diagram....4972
Control Panel Layout....4973
Air Control Functions....4974
Operation and Functions of Control Panel Switches....4975
Overview of Construction, Movement and Control of Major Parts of Automatic Air Conditioner System....4978
Overview of Automatic Control of Automatic Air Conditioner....4981
Troubleshooting....4985
Troubleshooting, Its Overview and Procedures....4985
Auto Air Conditioner Control Unit Power Supply Diagnosis....4986
Performance and Movement checklist for Automatic Air Conditioner Related Parts....4988
Troubleshooting With Self-Diagnosis Function....4990
Inspection By Failed Location....4994
Inspection of the Sensors....4994
Inspection of the Intake Actuator System....4998
Inspection of the Mix Actuator System....5001
Inspection of the Mode Actuator System....5004
Inspection of the Fan Motor System....5007
Inspection of the Heater Control System....5011
Inspection of the Magnetic Clutch System....5013
Condenser Fan Diagnosis....5016
Individual Inspection....5019
On-Vehicle Service....5024
Power Transistor....5024
Removal....5024
Installation....5024
Automatic Air Conditioner Control Unit....5024
Removal....5024
Installation....5024
In Car Sensor....5025
Removal....5025
Installation....5025
Ambient Sensor....5025
Removal....5025
Installation....5025
Sun Sensor....5026
Removal....5026
Installation....5026
Duct Sensor....5026
Removal....5026
Installation....5026
Mode Actuator....5027
Removal....5027
Installation....5027
Mix Actuator....5027
Removal....5027
Installation....5027
Intake Actuator....5028
Removal....5028
Installation....5028
Sec.2 STEERING....5029
2A POWER-ASSISTED STEERING SYSTEM....5029
Service Precaution....5030
Diagnosis....5030
General Description....5036
Power Steering System Test....5038
Maintenance....5039
Fluid Level....5039
Bleeding The Power Steering System....5039
Bleeding Procedure....5039
Flushing The Power Steering System....5040
Steering Wheel Free Play Inspection....5040
Front End Alignment Inspection and Adjustment....5040
Special Tools....5045
Power Steering Unit....5046
Power Steering Unit and Associated Parts....5046
Removal....5046
Installation....5047
Power Steering Unit Disassembled View....5048
Disassembly....5048
Inspection and Repair....5048
Reassembly....5048
Main Data and Specifications....5049
Special Tools....5049
Power Steering Pump....5050
Power Steering Pump and Associated Parts....5050
Removal....5050
Installation....5050
Power Steering Pump Disassembled View....5051
Disassembly....5051
Inspection and Repair....5052
Reassembly....5052
Main Data and Specifications....5054
Transfer Gear Assembly....5055
Transfer Gear Assembly and Associated Parts....5055
Removal....5055
Inspection and Repair....5055
Installation....5056
Supplemental Restraint System Steering Wheel & Column....5057
Service Precaution....5057
SRS Connectors....5057
Inflator Module....5059
Inflator Module and Associated Parts....5059
Removal....5059
Inspection and Repair....5060
Installation....5060
Steering Wheel....5061
Steering Wheel and Associated Parts....5061
Removal....5061
Installation....5063
Combination Switch....5064
Combination Switch and Associated Parts....5064
Removal....5064
Installation....5066
Lock Cylinder....5068
Lock Cylinder and Associated Parts....5068
Removal....5068
Installation....5070
System Inspection....5071
Steering Column....5072
Steering Column and Associated Parts....5072
Removal....5072
Insepction....5075
Installation....5076
System Inspection....5077
Supplemental Restraint System Steering Wheel & Column and Associated Parts....5078
Main Data and Specifications....5078
Special Tools....5078
Sec.3 SUSPENSION....5079
3C FRONT SUSPENSION....5079
Service Precaution....5079
General Description....5080
Diagnosis....5080
Shock Absorber....5084
Shock Absorber and Associated Parts....5084
Removal....5084
Inspection and Repair....5084
Installation....5084
Stabilizer Bar....5085
Stabilizer Bar and Associated Parts....5085
Removal....5085
Inspection and Repair....5085
Installation....5085
Torsion Bar....5086
Torsion Bar and Associated Parts....5086
Removal....5086
Inspection and Repair....5087
Installation....5087
Knuckle....5089
Knuckle and Associated Parts....5089
Removal....5089
Inspection and Repair....5090
Installation....5090
Upper Control Arm....5092
Upper Control Arm and Associated Parts....5092
Removal....5092
Inspection and Repair....5093
Installation....5093
Lower Control Arm....5096
Lower Control Arm and Associated Parts....5096
Removal....5096
Inspection and Repair....5097
Installation....5098
Upper Ball Joint....5100
Upper Ball Joint and Associated Parts....5100
Removal....5100
Inspection and Repair....5101
Installation....5101
Lower Ball Joint....5102
Lower Ball Joint and Associated Parts....5102
Removal....5102
Inspection and Repair....5103
Installation....5103
Main Data and Specifications....5104
Special Tools....5105
3D REAR SUSPENSION....5106
Service Precaution....5106
General Description....5106
Diagnosis....5107
Coil Spring....5110
Coil Spring and Associated Parts....5110
Removal....5110
Inspection and Repair....5111
Installation....5111
Shock Absorber....5112
Shock Absorber and Associated Parts....5112
Removal....5112
Inspection and Repair....5112
Installation....5112
Trailing Link....5113
Trailing Link and Associated Parts....5113
Removal....5113
Inspection and Repair....5113
Installation....5114
Upper Link....5115
Upper Link and Associated Parts....5115
Removal....5115
Inspection and Repair....5115
Installation....5116
Lateral Rod....5117
Lateral Rod and Associated Parts....5117
Removal....5117
Inspection and Repair....5117
Installation....5118
Stabilizer Bar....5119
Stabilizer Bar and Associated Parts....5119
Removal....5119
Inspection and Repair....5119
Installation....5120
Main Data and Specifications....5121
Special Tools....5123
3E WHEEL AND TIRE SYSTEM....5124
Service Precaution....5124
General Description....5125
Diagnosis....5126
Wheel....5134
Wheel and Associated Parts....5134
Removal....5134
Installation....5134
Tire....5135
Tire Replacement....5135
General Balance Procedure....5135
Balancing Wheel and Tire....5136
Main Data and Specifications....5137
3F INTELLIGENT SUSPENSION CONTROL....5138
Service Precaution....5139
General Description....5139
PIN ASSIGNMENT TABLE....5141
System Components....5141
Control Unit....5141
Actuator....5141
Adjustable Damping Force Shock Absorber....5141
Warning Lamp....5141
Vertical G-Sensor....5142
Lateral G-Sensor....5142
Acronyms and Abbreviations....5142
General Diagnosis....5142
General Information....5142
Service Precautions....5142
Computer System Service Precautions....5142
General Service Precautions....5142
Parts Handling....5142
FLASHING CODES....5143
CLEAR DTC....5144
INTERMITTENT CONDITIONS....5145
BULB CHECK....5145
DTC CHECK....5145
Basic Diagnosis Flow....5146
Circuit Diagram....5147
Parts Location....5150
Connector List....5151
Diagnostic Trouble Code (DTC) Identification....5153
DTC2 Actuator Coil Over Current....5154
Circuit Description....5154
Diagnostic Aids....5154
DTC3 Actuator Coil/Position Sensor Open Circuit or Short....5156
Circuit Description....5156
Diagnostic Aids....5156
DTC4 G-Sensor Open Circuit or Short....5159
Circuit Description....5159
Diagnostic Aids....5159
DTC5 Vehicle Speed Sensor Open Circuit or Short....5160
Circuit Description....5160
Diagnostic Aids....5160
DTC6 Stop Lamp Switch Open Circuit or Short....5162
Circuit Description....5162
Diagnostic Aids....5162
DTC7 Engine Speed Signal Open Circuit or Short....5164
Circuit Description....5164
Diagnostic Aids....5164
DTC9 Control Unit Abnormality....5165
Control Unit....5169
Control Unit and Associated Parts....5169
Removal....5169
Installation....5170
Front Actuator....5171
Front Actuator and Associated Parts....5171
Removal....5172
Inspection and Repair....5172
Installation....5172
Rear Shock Absorber....5173
Rear Shock Absorber and Associated Parts....5173
Removal....5174
Inspection and Repair....5174
Installation....5174
Sec.4 DRIVELINE/AXLE....5175
4A1 DIFFERENTIAL (FRONT)....5175
Service Precaution....5175
Front Drive Axle....5176
Diagnosis....5176
Pinion Shaft Oil Seal....5177
Pinion Shaft Oil Seal and Associated Parts....5177
Removal....5177
Inspection and Repair....5178
Installation....5178
Front Drive Axle Assembly....5179
Front Drive Axle Assembly and Associated Parts....5179
Removal....5180
Installation....5180
Differential Assembly....5182
Disassembled View....5182
Disassembly....5183
Reassembly....5185
Differential Cage Assembly....5194
Disassembled View....5194
Disassembly....5194
Inspection and Repair....5195
Reassembly....5196
Main Data and Specifications....5198
Special Tools....5201
4A2 DIFFERENTIAL (REAR)....5203
Service Precaution....5203
General Description....5204
Diagnosis....5205
Axle Housing....5207
Axle Housing and Associated Parts....5207
Removal....5207
Installation....5209
Axle Shaft, Oil Seal and Bearing....5209
Axle Shaft and Associated Parts....5209
Removal....5209
Inspection....5210
Installation....5210
Pinion Oil Seal....5212
Pinion Oil Seal and Associated Parts....5212
Removal....5212
Inspection and Repair....5213
Installation....5213
Differential Assembly....5215
Disassembled View....5215
Inspecting the Axle Before Disassembly....5216
Disassembly....5216
Inspection and Repair....5218
Reassembly....5219
Side Bearing Preload Adjustment....5223
Pinion Installation....5224
Determination of Backlash & Preload Shims....5225
Backlash Adjustment....5226
Gear Tooth Pattern Check....5227
Adjustments Affecting Tooth Contact....5228
Differential Case Assembly....5229
Disassembled View....5229
Disassembly....5230
Inspection and Repair....5230
Reassembly....5230
Limited Slip Differential Assembly....5231
Disassembled View....5231
Disassembly....5231
Inspection and Repair....5233
Reassembly....5233
Main Data And Specifications....5235
Special Tools....5237
4B1 DRIVELINE CONTROL SYSTEM....5239
Service Precaution....5239
Outline of Shift on The Fly System....5240
Functions of Indicator Lamp....5244
Diagnosis....5245
Shift On The Fly Electrical Equipment....5255
Axle Shaft Connection and Disconnection....5255
4WD Control Unit....5258
4WD Control Unit Associated Parts....5258
Removal....5258
Installation....5259
Shift On The Fly Controller....5260
Shift On The Fly Controller and Associated Parts....5260
Removal....5260
Installation....5260
4B2 DRIVELINE CONTROL SYSTEM (TOD)....5261
Service Precaution....5261
General Description....5262
Abbreviations....5263
System Components....5264
Parts Location....5264
Functions of TOD Switch and Indicator Lamp....5271
Diagnosis....5274
Basic Diagnostic Flow Chart....5278
Parts Location....5279
Circuit Diagram....5280
Connector List....5284
Checking Failed Pin....5286
Checking Failed TOD Control Unit Pin....5290
Diagnostic Trouble Codes....5295
Diagnosis from Trouble Codes....5296
Trouble Diagnosis Depending on The Status of TOD Indicator....5327
Diagnosis from Symptom....5362
4C DRIVE SHAFT SYSTEM....5379
Service Precaution....5379
General Description....5380
Diagnosis....5380
Front Hub and Disc....5381
Disassembled View....5381
Disassembly....5381
Inspection and Repair....5382
Reassembly....5383
Front Drive Shaft Joint....5386
Front Drive Shaft Joints Replacement....5386
Front Axle Drive Shaft....5387
Front Axle Drive Shaft and Associated Parts....5387
Disassembly....5388
Inspection And Repair....5389
Bushing Replacement....5389
Reassembly....5389
Shift On The Fly System....5392
Shift On The Fly System and Associated Parts....5392
Disassembly....5392
Inspection And Repair....5394
Reassembly....5396
Main Data and Specifications....5399
Special Tools....5401
Propeller Shaft....5403
General Description....5403
Universal Joint....5404
Diagnosis of Propeller Shaft and Universal Joint....5405
Front Propeller Shaft....5406
Front Propeller Shaft and Associated Parts....5406
Removal....5406
Installation....5407
Slip Joint Disassembly....5408
Universal Joint Disassembly....5409
Inspection and Repair....5410
Universal Joint Reassembly....5412
Slip Joint Reassembly....5413
Main Data and Specifications....5416
Rear Propeller Shaft....5417
Rear Propeller Shaft and Associated Parts....5417
Removal....5417
Installation....5417
Slip Joint Disassembly....5418
Universal Joint Disassembly....5419
Inspection....5421
Universal Joint Reassembly....5422
Slip Joint Reassembly....5423
Main Data and Specifications....5424
4D1 TRANSFER CASE....5425
Service Precaution....5425
Transfer Rear Oil Seal....5428
Transfer Rear Oil Seal and Associated Parts....5428
Removal....5428
Installation....5428
Transfer Case Assembly (A/T)....5430
Transfer Case Assembly (A/T) and Associated Parts....5430
Removal....5431
Installation....5432
Transfer Rear Case Assembly (A/T)....5435
Transfer Rear Case Assembly (A/T) and Associated Parts....5435
Removal....5435
Installation....5437
Transfer Rear Cover Assembly....5440
Disassembly....5440
Inspection and Repair....5441
Reassembly....5441
Detent, Shift Arm, and Interlock Pin (Transfer Case Assembly)....5443
Disassembled View....5443
Disassembly....5444
Inspection and Repair....5445
Reassembly....5445
Transfer Case Assembly....5447
Disassembled View....5447
Disassembly....5448
Inspection and Repair....5451
Reassembly....5454
Main Data and Specifications....5461
Special Tools....5464
4D2 TRANSFER CASE (TOD)....5466
Service Precaution....5466
General Description....5467
Removal and Installation of Tfansfer Case Assembly....5468
Removal....5469
Installation....5469
Transfer Rear Oil Seal....5471
Removal....5471
Installation....5471
TOD Control Unit....5473
Removal....5473
Installation....5473
Unit Repair....5474
Disassembly and Reassembly of Major Components....5474
Disassembly....5475
Reassembly....5475
Transfer Cover Assembly....5478
Disassembly....5478
Inspection and Repair....5479
Reassembly....5480
Clutch Pack and Clutch Cam (Transfer Case Assembly)....5481
Disassembly....5481
Reassembly....5483
Chain, Sprocket and Mechanical Lock (Transfer Case Assembly)....5485
Disassembly....5486
Reassembly....5487
Transfer Case Assembly....5489
Disassembly....5489
Reassembly....5491
Inspection and Repair (Transfer Case Assembly)....5493
Main Data and Specification....5497
General Specification....5497
Torque Specifications....5498
Special Tools....5501
Sec.5 BRAKES....5502
5A BRAKE CONTROL SYSTEM....5502
Service Precaution....5503
General Description....5504
Functional Description....5505
System Components....5511
Electronic Hydraulic Control Unit (EHCU)....5511
ABS Warning Light....5511
Wheel Speed Sensor....5511
G-Sensor....5511
Normal and Anti-lock Braking....5511
Brake Pedal Travel....5511
Acronyms and Abbreviations....5512
General Diagnosis....5512
General Information....5512
ABS Service Precautions....5512
Computer System Service Precautions....5512
General Service Precautions....5512
Note on Intermittents....5513
Test Driving ABS Complaint Vehicles....5513
“ABS" Warning Light....5513
Normal Operation....5513
Tech 2 Scan Tool....5514
DATA LIST....5517
ACTUATOR TEST....5518
Basic Diagnostic Flow Chart....5524
Basic Inspection Procedure....5524
EHCU Connector Pin-out Checks....5525
Circuit Diagram....5526
Connector List....5528
Part Location....5530
Symptom Diagnosis....5531
Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate....5531
Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)....5532
Chart A-2 Uneven Braking Occurs While ABS Works....5532
Chart TA-2 Uneven Braking Occurs While ABS Works (Use TECH 2)....5532
Chart A-3, TA-3 The Wheels Are Locked....5533
Chart A-3, TA-3 The Wheels Are Locked....5533
Chart A-5, TA-5 Braking Sound (From EHCU) Is Heard While Not Braking....5534
Diagnosis By “ABS" Warning Light Illumination Pattern....5537
Diagnostic Trouble Codes (DTCs)....5538
Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated.....5540
Chart B-2 CPU Error (DTC 14 (Flash out) / C0271, C0272, C0273, C0284 (Serial communications))....5540
Chart B-3 Low or High Ignition Voltage (DTC 15 (Flash out) / C0277, 0278 (Serial communications))....5541
Chart B-4 Excessive Dump Time (DTC 17 (Flash out) / C0269 (Serial communications))....5541
Chart B-5 Excessive Isolation Time (DTC 18 (Flash out) / C0274 (Serial communications))....5541
Chart B-6 G-Sensor Output Failure (DTC 21 (Flash out) / C0276 (Serial communications))....5542
Chart B-7 Brake Switch Failure (DTC 22 (Flash out) / C0281 (Serial communications))....5542
Chart B-8 2WD Controller in 4WD Vehicle Controller (DTC 13 (Flash out) / C0285 (Serial communications)), 4WD State Input Sign....5543
Chart B-9 Pump Motor Failure (DTC 32 (Flash out) / C0267, C0268 (Serial communications))....5543
Chart B-10 EHCU Valve Relay Failure (DTC 35 (Flash out) / C0265, C0266 (Serial communications))....5544
Chart B-11 FL Isolation Solenoid Coil Failure (DTC 41 (Flash out) / C0245, C0247 (Serial communications))....5544
Chart B-12 FL Dump Solenoid Coil Failure (DTC 42 (Flash out) / C0246, C0248 (Serial communications))....5544
Chart B-13 FR Isolation Solenoid Coil Failure (DTC 43 (Flash out) / C0241, C0243 (Serial communications))....5545
Chart B-14 FR Dump Solenoid Coil Failure (DTC 44(Flash out) / C0242, C0244 (Serial communications))....5545
Chart B-15 Rear Isolation Solenoid Coil Failure (DTC 45 (Flash out) / C0251, C0253 (Serial communications))....5545
Chart B-16 Rear Dump Solenoid Coil Failure (DTC 46 (Flash out) / C0252, C0254 (Serial communications))....5546
Chart B-17 FL Speed Sensor Open or Shorted (DTC 51 (Flash out) / C0225 (Serial communications))....5546
Chart B-18 FR Speed Sensor Open or Shorted (DTC 52 (Flash out) / C0221 (Serial communications))....5547
Chart B-19 Rear Speed Sensor Open or Shorted (DTC 53 (Flash out) / C0235 (Serial....5548
Chart B-20 FL Speed Sensor Missing (DTC 61 (Flash out) / C0226, C0227 (Serial communications))....5549
Chart B-21 FR Speed Sensor Missing (DTC 62 (Flash out) / C0222, C0223 (Serial communications))....5550
Chart B-22 Rear Speed Sensor Missing (DTC 63 (Flash out) / C0236, C0237 (Serial communications))....5551
Chart B-23 Simultaneous Drop-out of Front Speed Sensor Signal (DTC 64 (Flash out) / C0229 (Serial communications))....5552
Chart B-24 Wheel Speed Input Abnormality (DTC 65 (Flash out) / C0238 (Serial communications))....5553
Chart C-1-1 FL Sensor Output Inspection Procedure....5554
Chart C-1-2 FR Sensor Output Inspection Procedure....5555
Chart C-1-3 Rear Sensor Output Inspection Procedure....5556
Chart TC-1 Sensor Output Inspection Procedure....5556
5B ANTI-LOCK BRAKE SYSTEM....5558
Service Precaution....5558
Electronic Hydraulic Control Unit....5559
Electronic Hydraulic Control Unit and Associated Parts....5559
Removal....5559
Disassembled View....5560
Disassembly....5560
Reassembly....5560
Installation....5560
Front Wheel Speed Sensor....5561
Front Wheel Speed Sensor and Associated Parts....5561
Removal....5561
Inspection and Repair....5561
Installation....5561
Rear Wheel Speed Sensor....5562
Removal....5562
Inspection and Repair....5562
Installation....5562
5C POWER-ASSISTED BRAKE SYSTEM....5563
Service Precaution....5564
General Description....5564
Diagnosis....5567
General Diagnosis....5568
Hydraulic Brakes....5571
Filling Master Cylinder Reservoir....5571
Deterioration of Brake Fluid....5571
Leakage of Brake Fluid....5571
Bleeding Brake Hydraulic System....5571
Flushing Brake Hydraulic System....5572
Brake Pipes and Hoses....5572
Brake Hose Inspection....5572
Front Caliper Brake Hose....5573
Front Caliper Brake Hose and Associated Parts....5573
Removal....5573
Installation....5573
Rear Axle Brake Hose....5574
Rear Axle Brake Hose and Associated Parts....5574
Removal....5574
Installation....5574
Brake Pipe....5575
Removal....5575
Installation....5575
P & B (Proportioning and Bypass) Valve....5576
P & B (Proportioning and Bypass) Valve Sectional View....5576
Removal....5576
Installation....5576
Main Data and Specifications....5577
Brake Pedal....5578
Checking Pedal Height....5578
Checking Pedal Travel....5578
Brake Pedal and Associated Parts....5579
Removal....5579
Installation....5579
Stoplight Switch....5580
Parts Location....5580
Removal....5580
Installation....5580
Main Data and Specifications....5581
Fluid Reservoir Tank....5582
Fluid Reservoir Tank and Associated Parts....5582
Removal....5582
Installation....5582
Master Cylinder Assembly....5583
Master Cylinder Assembly and Associated Parts....5583
Removal....5583
Inspection and Repair....5583
Installation....5585
Main Data and Specifications....5585
Special Tools....5585
Vacuum Booster Assembly....5586
Vacuum Booster Assembly and Associated Parts....5586
Removal....5586
Inspection and Repair....5586
Installation....5587
Exterior Components....5589
Exterior Components and Associated Parts....5589
Removal....5589
Inspection and Repair....5590
Installation....5590
Vacuum Booster Overhaul....5590
Vacuum Booster....5590
Main Data and Specifications....5591
Special Tools....5592
Front Disc Brake Pads....5593
Front Disc Brake Pads Inspection....5593
Removal....5594
Installation....5594
Front Disc Brake Rotor....5596
Inspection....5596
Replacing Brake Rotors....5596
Refinishing Brake Rotors....5596
Front Disc Brake Caliper Assembly....5598
Front Disc Brake Caliper Assembly and Associated Parts....5598
Removal....5598
Installation....5599
Front Disc Brake Caliper....5601
Front Disc Brake Caliper Disassembled View....5601
Disassembly....5601
Inspection and Repair....5602
Reassembly....5602
Main Data and Specifications....5604
Rear Disc Brake Pads....5605
Brake Pads Inspection....5605
Brake Pads and Associated Parts....5605
Removal....5606
Installation....5606
Rear Disc Brake Rotor....5608
Inspection....5608
Replacing Brake Rotors....5608
Refinishing Brake Rotors....5608
Rear Drum (In Disc) Inside Diameter Check....5609
Rear Disc Brake Caliper Assembly....5610
Rear Disc Brake Caliper Assembly and Associated Parts....5610
Removal....5610
Installation....5611
Rear Disc Brake Caliper....5613
Rear Disc Brake Caliper Disassembled View....5613
Disassembly....5613
Inspection and Repair....5614
Reassembly....5614
Main Data and Specifications....5616
5D PARKING BRAKE SYSTEM....5617
Service Precaution....5617
General Description....5617
Operation....5618
Parking Brake Lever and Front Cable....5619
Parking Brake Lever Assembly and Associated Parts....5619
Removal....5619
Installation....5619
Parking Brake Rear Cable....5620
Parking Brake Rear Cable and Associated Parts....5620
Removal....5621
Installation....5621
Inspection and Repair....5622
Parking Brake Adjustment....5622
Main Data and Specifications....5623
Sec.6 ENGINE....5624
6A ENGINE MECHANICAL....5624
Service Precaution....5625
General Description....5626
Engine Diagnosis....5627
Drive Belt (Serpentine Belt)....5642
Removal....5642
Inspection and Repair....5644
Installation....5645
Cylinder Head Cover LH....5646
Removal....5646
Installation....5647
Cylinder Head Cover RH....5648
Removal....5648
Installation....5648
Common Chamber....5649
Removal....5649
Installation....5649
Exhaust Manifold LH....5651
Removal....5651
Installation....5651
Exhaust Manifold RH....5652
Removal....5652
Installation....5653
Crankshaft Pulley....5654
Removal....5654
Installation....5654
Timing Belt....5655
Removal....5655
Installation....5656
Camshaft....5660
Removal....5660
Installation....5660
Cylinder Head....5664
Removal....5664
Installation....5664
Valve Stem Oil Controller , Valve Spring and Valve Guide....5666
Removal....5666
Installation....5666
Piston, Piston Ring and Connecting Rod....5667
Removal....5667
Installation....5668
Crankshaft and Main Bearings....5669
Removal....5669
Installation....5670
Rear Oil Seal....5674
Removal....5674
Installation....5674
Engine Assembly....5676
Removal....5676
Installation....5677
Cylinder Head....5679
Cylinder Head and Associated Parts....5679
Disassembly....5679
Clean....5680
Inspection and Repair....5680
Reassembly....5680
Valve Spring, Oil Controller, Valve, Valve Guide....5681
Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts....5681
Disassembly....5681
Inspection and Repair....5682
Reassembly....5685
Valve Clearance Adjustments....5686
Camshaft....5688
Camshaft and Associated Parts....5688
Disassembly....5688
Inspection and Repair....5689
Reassembly....5691
Crankshaft....5695
Crankshaft and Associated Parts....5695
Disassembly....5695
Inspection and Repair....5696
Inspection and Repair....5697
Reassembly....5699
Piston and Connecting Rod....5703
Piston, Connecting Rod and Associate Parts....5703
Disassembly....5703
Inspection and Repair....5704
Reassembly....5708
Cylinder Block....5711
Cylinder Block and Associated Parts....5711
Disassembly....5711
Inspection and Repair....5712
Reassembly....5713
Main Data and Specification....5716
Special Tool....5722
6B ENGINE COOLING....5724
Service Precaution....5724
General Description....5725
Diagnosis....5728
Draining and Refilling Cooling System....5729
Engine coolant change....5729
Water Pump....5730
Water Pump and Associated Parts....5730
Removal....5730
Inspection....5730
Installation....5730
Thermostat....5731
Thermostat and Associated Parts....5731
Removal....5731
Inspection....5731
Installation....5731
Radiator....5732
Radiator and Associated Parts....5732
Removal....5732
Inspection....5733
Installation....5734
Drive Belt and Cooling Fan....5735
Drive Belt and Associated Parts....5735
Inspection....5735
Installation....5735
Main Data and Specifications....5736
6C ENGINE FUEL....5737
Service Precaution....5737
General Description....5738
Fuel Metering....5739
Fuel Filter....5740
Removal....5740
Inspection....5740
Installation....5740
Inspection....5740
In‐Tank Fuel Filter....5740
Fuel Pump Flow Test....5741
Fuel Pump....5742
Fuel Pump and Associated Parts....5742
Removal....5742
Installation....5742
Fuel Tube / Quick ‐ Connector Fittings....5743
Precautions....5743
Cautions During Work....5743
Removal....5743
Reuse of Quick‐Connector....5744
Assembling Advice....5744
Fuel Pump Relay....5744
General Description....5744
Fuel Tank....5745
Fuel Tank and Associated Parts....5745
Removal....5745
Installation....5746
Fuel Gauge Unit....5746
Removal and Installation....5746
Fuel Filler Cap....5746
General Description....5746
Inspection....5746
Main Data and Specifications....5747
6D1 ENGINE ELECTRICAL....5748
Service Precaution....5748
Battery....5749
General Description....5749
Diagnosis....5749
Battery Charging....5750
Jump Starting....5750
Battery Removal....5751
Battery Installation....5751
Main Data and Specifications....5752
6D2 IGNITION SYSTEM....5753
Service Precaution....5753
General Description....5754
Diagnosis....5754
Ignition Coil....5755
Removal....5755
Inspection and Repair....5755
Installation....5755
Spark Plug....5757
Inspection....5757
Replacement spark plugs....5757
Crankshaft Position Sensor....5758
Removal....5758
Installation....5758
Main Data and Specifications....5759
6D3 STARTING AND CHARGING SYSTEM....5760
Service Precaution....5760
Starting System....5761
General Description....5761
Diagnosis....5763
Starter....5764
Removal....5764
Installation....5764
Disassembled View....5765
Disassembly....5766
Inspection and Repair....5768
Reassembly....5772
Main Data and Specifications....5774
Charging System....5777
General Description....5777
General On‐Vehicle Inspection....5777
Generator....5778
Removal....5778
Inspection....5778
Installation....5779
Disassembled View....5779
Disassembly....5780
Inspection and Repair....5781
Reassembly....5783
Bench Test....5784
Main Data and Specifications....5785
6E 3.2L ENGINE DRIVEABILITY AND EMISSIONS....5786
Specifications....5790
Tightening Specifications....5790
Diagrams and Schematics....5791
PCM Wiring Diagram (1 of 7)....5791
PCM Wiring Diagram (2 of 7)....5792
PCM Wiring Diagram (3 of 7)....5793
PCM Wiring Diagram (4 of 7)....5794
PCM Wiring Diagram (5 of 7)....5795
PCM Wiring Diagram (6 of 7)....5796
PCM Wiring Diagram (7 of 7)....5797
PCM Pinouts....5798
PCM Pinout Table, 80-Way Blue Connector-Row “F1-20”....5798
PCM Pinout Table, 80-Way Blue Connector-Row “F20-40”....5799
PCM Pinout Table, 80-Way Blue Connector-Row “F41-60”....5800
PCM Pinout Table, 80-Way Blue Connector-Row “F61-80”....5801
PCM Pinout Table, 80-Way Red Connector-Row “S1-20”....5803
PCM Pinout Table, 80-Way Red Connector-Row “S21-40”....5805
PCM Pinout Table, 80-Way Red Connector-Row “S41-60”....5807
PCM Pinout Table, 80-Way Red Connector-Row “S61-80”....5808
Component Locators....5810
Engine Component Locator Table....5811
Undercarriage Component Locator....5812
Undercarriage Component Locator Table....5812
Fuse and Relay Panel (Underhood Electrical Center)....5813
Sensors and Miscellaneous Component Locators....5814
Diagnosis....5817
Strategy-Based Diagnostics....5817
Strategy-Based Diagnostics....5817
DTC Stored....5817
No DTC....5817
No Matching Symptom....5817
Intermittents....5817
No Trouble Found....5817
Verifying Vehicle Repair....5817
General Service Information....5817
OBD Serviceability Issues....5817
Visual / Physical Engine Compartment Inspection....5818
Basic Knowledge of Tools Required....5818
Serial Data Communications....5818
Class 2 Serial Data Communications....5818
On-Board Diagnostic (OBD)....5819
On-Board Diagnostic Tests....5819
Comprehensive Component Monitor Diagnostic Operation....5819
The Diagnostic Executive....5820
DTC Types....5821
Decimal/Binary/Hexadecimal Conversions....5822
Verifying Vehicle Repair....5822
Reading Diagnostic Trouble Codes Using The Tech 2 Scan Tool....5822
Tech 2....5824
Tech 2 Features....5825
Getting Started....5825
Operating Procedure (For Example)....5826
DTC Modes....5827
DTC Information Mode....5827
Miscellaneous Test....5828
Lamps Test....5828
Relays Test....5829
EVAP Test....5830
Fuel System Test....5831
Instruments Test....5833
EGR Control Test....5835
Variable Intake Manifold Solenoid Test....5836
Injector Balance Test....5837
Plotting Snapshot Graph....5837
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)....5838
Flow Chart for Snapshot Replay (Plotting Graph)....5839
Primary System-Based Diagnostic....5840
Primary System-Based Diagnostic....5840
Fuel Control Heated Oxygen Sensor....5840
HO2S Heater....5840
On-Board Diagnostic (OBD) System Check....5841
A/C Clutch Control Circuit Diagnosis....5844
Electronic Ignition System Diagnosis....5849
Visual Check of The Evaporative Emission Canister....5849
Fuel Metering System Check....5849
Powertrain Control Module (PCM) Diagnosis....5849
Multiple PCM Information Sensor DTCs Set....5849
Exhaust Gas Recirculation (EGR) Diagnosis....5853
Engine Tech 2 Data Definitions and Ranges....5853
Typical Scan Data Values....5855
No Malfunction Indicator Lamp (MIL)....5860
Malfunction Indicator Lamp (MIL) “ON” Steady....5863
No Reduced Power Lamp (RPL)....5865
Reduced Power Lamp (RPL) “ON” Steady....5869
Engine Cranks But Will Not Run....5872
Fuel System Electrical Test....5879
Electric Throttle Control (ETC) System Check....5883
Exhaust Gas Recirculation (EGR) System Check....5892
Manifold Absolute Pressure (MAP) Output Check....5894
Evaporative (EVAP) Emissions Canister Purge Valve Check....5896
PCM Diagnostic Trouble Codes....5899
(DTC) P0101 MAF System Performance....5902
(DTC) P0102 MAF Sensor Circuit Low Frequency....5905
(DTC) P0103 MAF Sensor Circuit High Frequency....5908
(DTC) P0106 MAP System Performance....5911
(DTC) P0107 MAP Sensor Circuit Low Voltage....5914
(DTC) P0108 MAP Sensor Circuit High Voltage....5917
(DTC) P0112 IAT Sensor Circuit Low Voltage....5920
(DTC) P0113 IAT Sensor Circuit High Voltage....5923
(DTC) P0117 ECT Sensor Circuit Low Voltage....5926
(DTC) P0118 ECT Sensor Circuit High Voltage....5929
(DTC) P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1....5932
(DTC) P0132 HO2S Circuit High Voltage Bank 1 Sensor 1....5935
(DTC) P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1....5938
(DTC) P0135 HO2S Heater Circuit Bank 1 Sensor 1....5941
(DTC) P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1....5944
(DTC) P0152 HO2S Circuit High Voltage Bank 2 Sensor 1....5947
(DTC) P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1....5950
(DTC) P0155 HO2S Heater Circuit Open Bank 2 Sensor 1....5953
(DTC) P0171 Fuel Trim System Lean Bank 1....5956
(DTC) P0172 Fuel Trim System Rich Bank 1....5960
(DTC) P0174 Fuel Trim System Lean Bank 2....5964
(DTC) P0175 Fuel Trim System Rich Bank 2....5968
(DTC) P0201 Injector 1 Control Circuit....5972
(DTC) P0202 Injector 2 Control Circuit....5975
(DTC) P0203 Injector 3 Control Circuit....5978
(DTC) P0204 Injector 4 Control Circuit....5981
(DTC) P0205 Injector 5 Control Circuit....5984
(DTC) P0206 Injector 6 Control Circuit....5987
(DTC) P0300 Engine Misfire Detected....5990
(DTC) P0301 Cylinder Misfire Detected....5994
(DTC) P0302 Cylinder Misfire Detected....5996
(DTC) P0303 Cylinder Misfire Detected....5998
(DTC) P0304 Cylinder Misfire Detected....6000
(DTC) P0305 Cylinder Misfire Detected....6002
(DTC) P0306 Cylinder Misfire Detected....6004
(DTC) P0325 ION Sensing Module/ION Sensing Knock Intensity Circuit Fault....6006
(DTC) P0336 58X Reference Signal Circuit....6009
(DTC) P0337 CKP Sensor Circuit Low Frequency....6012
(DTC) P0351 Ignition 1 Control Circuit....6015
(DTC) P0352 Ignition 2 Control Circuit....6018
(DTC) P0353 Ignition 3 Control Circuit....6021
(DTC) P0354 Ignition 4 Control Circuit....6024
(DTC) P0355 Ignition 5 Control Circuit....6027
(DTC) P0356 Ignition 6 Control Circuit....6030
(DTC) P0402 EGR Pintle Crank Error....6033
(DTC) P0404 EGR Open Stuck....6035
(DTC) P0405 EGR Low Voltage....6037
(DTC) P0406 EGR High Voltage....6040
(DTC) P0502 VSS Circuit Low Input....6043
(DTC) P0506 Idle Air Control System Low RPM....6046
(DTC) P0507 Idle Air Control System High RPM....6049
(DTC) P0562 System Voltage Low....6052
(DTC) P0563 System Voltage High....6054
(DTC) P0565 Cruise Main Switch Circuit Error....6056
(DTC) P0566 Cruise Cancel Switch Circuit Error....6058
(DTC) P0567 Cruise Resume Switch Circuit Error....6060
(DTC) P0571 No Brake Switch Signal....6062
(DTC) P0601 PCM Memory....6064
(DTC) P0602 PCM Programming Error....6066
(DTC) P0604 PCM RAM Error....6068
(DTC) P0606 PCM Internal Performance....6070
(DTC) P1106 MAP Sensor Circuit Intermittent High Voltage....6072
(DTC) P1107 MAP Circuit Intermittent Low Voltage....6074
(DTC) P1111 IAT Sensor Circuit Intermittent High Voltage....6076
(DTC) P1112 IAT Sensor Circuit Intermittent Low Voltage....6079
(DTC) P1114 ECT Sensor Circuit Intermittent Low Voltage....6081
(DTC) P1115 ECT Sensor Circuit Intermittent High Voltage....6083
(DTC) P1120-TPS 1 Throttle Position Sensor (TPS1) Output Abnormal....6086
(DTC) P1125 ETC (Electric Throttle Control) Limit Performance Mode....6089
(DTC) P1167 Fuel System Rich During Decel Fuel Cut Off (Bank 1)....6092
(DTC) P1169 Fuel System Rich During Decel Fuel Cut Off (Bank 2)....6094
(DTC) P1171 Fuel System Lean During Accelerator....6096
(DTC) P1220 Throttle Position Senser2 (TPS2) Circuit Fault....6099
(DTC) P1221 TPS1-TPS2 Correlation(Circuit Performance)....6102
(DTC) P1271 APS 1-2 Correlation Error....6105
(DTC) P1272 APS 2-3 Correlation Error....6108
(DTC) P1273 APS 1-3 Correlation Error....6111
(DTC) P1275 APS 1 Output Fault....6114
(DTC) P1280 APS 2 Output Fault....6116
(DTC) P1285 APS 3 Output Fault....6118
(DTC) P1290 ETC Forced Idle Mode....6120
(DTC) P1295 ETC Power Management Mode....6123
(DTC) P1299 ETC Forced Engine Shutdown Mode....6127
(DTC) P1310 ION Sensing Module Diagnosis....6131
(DTC) P1311 ION Sensing Module SEC Line 1 Circuit Fault....6134
(DTC) P1312 ION Sensing Module SEC Line 2 Circuit Fault....6137
(DTC) P1326 ION Sensing Module Combustion Quality Input Circuit Fault....6140
(DTC) P1340 ION Sensing Module Cylinder ID Fault (Cylinder Synchronization Fail)....6143
(DTC) P1404 EGR Stuck Closed....6146
(DTC) P1514 TPS-MAF Correlation Error....6149
(DTC) P1515 Command - Actual TPS Correlation Error....6153
(DTC) P1516 Command - Actual TPS Correlation Error....6156
(DTC) P1523 Actuator Control Return Performance....6159
(DTC) P1571 Brake Switch No Operation....6162
(DTC) P1635 Reference Voltage # 1 Circuit Fault....6164
(DTC) P1639 Reference Voltage # 2 Circuit Fault....6166
(DTC) P1640 Driver-1-Output Circuit Fault (ODM)....6168
(DTC) P1650 Quad Driver Module “A” Fault....6171
Default Matrix Table....6201
On Vehicle Service Crankshaft Position (CKP) Sensor....6204
Engine Coolant Temperature (ECT) Sensor....6204
Heated Oxygen Sensor (HO2S)....6205
Intake Air Temperature (IAT) Sensor....6207
ION Sensing Module....6208
Mass Air Flow (MAF) Sensor....6209
Manifold Absolute Pressure (MAP) Sensor....6210
Malfunction Indicator Lamp (MIL)....6211
Reduced Power Lamp....6211
Powertrain Control Module....6211
Service Precaution....6211
Throttle Position (TP) Sensor....6212
Vehicle Speed Sensor (VSS)....6213
Air Cleaner/Air Filter....6214
Common Chamber....6215
Accelerator Pedal Replacement....6215
Accelerator Position Sensor Replacement....6216
Accelerator Position Sensor Adjustment....6217
Fuel Filler Cap....6218
Fuel Filter....6218
Fuel Gauge Unit....6219
Fuel Injectors....6220
Fuel Metering System....6221
Fuel Pump Assembly....6221
Fuel Pump Relay....6221
Fuel Rail Assembly....6222
Fuel Tank....6223
Throttle Body (TB)....6223
Electronic Ignition System....6225
Catalytic Converter....6226
Air Conditioning Thermo Relay....6226
EVAP Canister....6227
EVAP Canister Purge Solenoid....6229
Linear Exhaust Gas Recirculation (EGR) Valve....6230
Positive Crankcase Ventilation (PCV) Valve....6231
Wiring and Connectors....6231
PCM Connectors and Terminals....6232
Wire Harness Repair: Twisted Shielded Cable....6232
Twisted Leads....6233
Weather-Pack Connector....6234
Com-Pack III....6235
Metri-Pack....6236
General Description (PCM and Sensors)....6237
General Description (Air Induction)....6241
General Description (Fuel Metering)....6242
General Description (Electronic Ignition System)....6244
A/C Clutch Diagnosis....6247
General Description (Evaporative (EVAP) Emission System)....6248
General Description (Exhaust Gas Recirculation (EGR) System)....6248
General Description (Positive Crankcase Ventilation (PCV) System)....6249
Special Tools....6251
6F ENGINE EXHAUST (6VD1 3.2L)....6252
Service Precaution....6252
General Description....6253
Three Way Catalytic Converter RH and Forked Exhaust Pipe....6254
Three Way Catalytic Converter RH and Forked Exhaust Pipe and Associated Parts....6254
Removal....6254
Installation....6254
Three Way Catalytic Converter LH and Forked Exhaust Pipe....6255
Three Way Catalytic Converter LH and Forked Exhaust Pipe and Associated Parts....6255
Removal....6255
Installation....6255
Forked Exhaust Pipe....6256
Forked Exhaust Pipe and Associated Parts....6256
Removal....6256
Installation....6256
Exhaust Silencer....6257
Exhaust Silencer and Associated Parts....6257
Removal....6257
Installation....6257
Rear Exhaust pipe....6258
Rear Exhaust pipe and Associated Parts....6258
Removal....6258
Installation....6258
Main Data and Specifications....6259
6G ENGINE LUBRICATION....6260
Service Precaution....6260
General Description....6261
Oil Pump....6262
Oil Pump and Associated Parts....6262
Oil Pump and Associated Parts....6263
Inspection and Repair....6263
Reassembly....6264
Oil Pan and Crankcase....6266
Removal....6266
Installation....6266
Oil Pump....6269
Removal....6269
Installation....6269
Oil Pump Oil Seal....6271
Removal....6271
Installation....6271
Oil Filter....6272
Removal....6272
Installation....6272
Main Data and Specification....6273
Special Tool....6274
6H ENGINE SPEED CONTROL SYSTEM....6275
Service Precaution....6275
Accelerator Pedal....6276
Accelerator Pedal and Associated Parts....6276
Removal....6276
Installation....6276
6J INDUCTION (6VD1 3.2L)....6277
Service Precaution....6277
Air Cleaner Element....6278
Removal....6278
Inspection....6278
Installation....6278
Sec.7 TRANSMISSION....6279
7A AUTOMATIC TRANSMISSION (4L30-E)....6279
Service Precaution....6280
Construction....6281
Range Reference Chart....6282
Normal Operation of 2001 4L30-E Transmission....6283
Diagnosis....6283
Driver Information....6283
General Diagnosis Procedure....6286
Preliminary Inspection Chart....6287
Checking Transmission Fluid Level and Condition....6288
Test Driving....6289
Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart....6290
Mechanical / Hydraulic Diagnosis Symptoms Index....6291
Stall Test....6300
Line Pressure Test....6301
Shift Speed Chart....6302
Lockup Speed Chart....6303
Changing Transmission Fluid....6304
Selector Lever....6304
Inspection....6304
Removal....6305
Installation....6306
Select Cable....6306
Removal....6306
Installation....6309
Shift Lock Cable....6311
Removal....6311
Installation....6311
Mode Switch....6313
Removal....6313
Installation....6313
Transmission (With Transfer Case)....6315
Transmission and Associated Parts....6315
Removal....6316
Installation....6320
Solenoid (Main Case Valve Body)....6324
Removal....6324
Installation....6324
Solenoid (Adapter Case Valve Body)....6325
Removal....6325
Installation....6325
Valve Body Assembly (Main Case)....6326
Removal....6326
Installation....6326
Valve Body Assembly (Adapter Case)....6327
Removal....6327
Installation....6327
Powertrain Control Module (PCM)....6328
Removal....6328
Installation....6328
Speed Sensor (Extension Housing)....6329
Removal....6329
Installation....6329
Transmission Oil Temperature Sensor (Main Case)....6330
Removal....6330
Installation....6330
Front Oil Seal (Converter Housing)....6331
Removal....6331
Installation....6331
Transmission (4L30‐E)....6332
Disassembly....6332
Reassembly....6336
Converter Housing and Oil Pump Assembly....6346
Disassembled View....6346
Disassembly....6346
Inspection and Repair....6346
Reassembly....6346
Oil Pump....6347
Disassembled View....6347
Disassembly....6347
Inspection and Repair....6347
Reassembly....6347
Main Case Valve Body....6348
Disassembled View....6348
Disassembly....6349
Inspection and Repair....6349
Reassembly....6349
Adapter Case Valve Body....6350
Disassembled View....6350
Disassembly....6350
Inspection and Repair....6350
Reassembly....6350
Third Clutch and Sprag Unit....6351
Disassembled View....6351
Disassembly....6351
Inspection and Repair....6352
Reassembly....6352
Third Clutch....6352
Disassembled View....6352
Disassemble....6353
Inspection and Repair....6353
Reassembly....6353
Sprag Unit....6354
Disassembled View....6354
Disassembly....6354
Inspection and Repair....6354
Reassembly....6354
Second Clutch....6355
Disassembled View....6355
Disassembly....6355
Inspection and Repair....6356
Reassembly....6356
3‐4 Accumulator Piston....6357
Disassembled View....6357
Disassembly....6357
Inspection and Repair....6358
Reassembly....6358
Reverse Clutch Piston and Center Support....6359
Disassembled View....6359
Disassembly....6360
Inspection and Repair....6360
Reassembly....6360
Overrun Clutch and Turbine Shaft....6361
Disassembled View....6361
Disassembly....6362
Inspection and Repair....6362
Reassembly....6362
Main Data and Specification....6364
General Specifications....6364
Torque Specifications....6365
Special Tools....6368
4L30-E Parts List....6371
7A1 TRANSMISSION CONTROL SYSTEM (4L30‐E)....6379
Service Precaution....6380
General Description....6380
Electronic Control Diagram....6381
Powertrain Control Module (PCM)....6382
Control System Diagram....6383
Shift Control....6384
Band Apply Control....6384
Torque Converter Clutch Control....6384
Line Pressure Control....6384
On‐Board Diagnostic System....6384
Fail Safe Mechanism....6384
Torque Management Control....6384
ATF Warning Control....6384
Reverse Lock Out Control....6384
Downhill Control....6384
Uphill Control....6384
Shift Mode Control....6385
Gear Shift Control....6386
Winter Drive Mode....6387
Backup Mode....6387
Functions of Input / Output Components....6388
Diagnosis....6389
Electronic Diagnosis....6389
Check Trans Indicator....6389
Diagnostic Check....6389
“Check Trans” Check....6390
Tech 2 OBD II Connection....6391
Transmission Data....6396
Flashing Code....6397
OBD II Diagnostic Management System....6398
16-Terminal Data Link Connector (DLC )....6399
Malfunction Indicator Lamp (MIL)....6400
DTC Types....6400
Clear DTC....6401
DTC Check....6401
PCM Precaution....6401
Information On PCM....6401
Intermittent Conditions....6402
Transmission and PCM Identification....6403
Diagnostic Trouble Code (DTC) Identification....6404
DTC P0218/Flashing Code 71 Transmission Fluid Over Temperature....6405
DTC P0705/Flashing Code 73 Transmission Range Switch (Mode Switch) Illegal Position....6407
DTC P0706/Flashing Code 74 Transmission Range Switch (Mode Switch) Performance....6410
DTC P0712/Flashing Code 75 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input....6413
DTC P0713/Flashing Code 76 Transmission Fluid Temperature (TFT) Sensor Circuit High Input....6416
DTC P0719/Flashing Code 77 TCC Brake Switch Circuit High (Stuck On)....6419
DTC P0722/Flashing Code 78 Transmission Output Speed Sensor (OSS) Low Input....6422
DTC P0723/Flashing Code 79 Transmission Output Speed Sensor (OSS) Intermittent....6425
DTC P0730/Flashing Code 81 Transmission Incorrect Gear Ratio....6428
DTC P0748/Flashing Code 82 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical....6431
DTC P0753/Flashing Code 83 Shift Solenoid A Electrical....6433
DTC P0758/Flashing Code 84 Shift Solenoid B Electrical....6436
DTC P1850/Flashing Code 88 Brake Band Apply Solenoid Malfunction....6440
DTC P1860/Flashing Code 89 TCC Solenoid Electrical....6443
Circuit Diagram....6446
Parts Location....6448
Harness Connector Faces....6449
Transmission Fluid Temperature (TFT) Sensor Specifications....6451
7B MANUAL TRANSMISSION MUA 5C (4X4)....6452
Service Precaution....6452
General Description....6453
Diagnosis (MUA)....6454
Transmission (MUA)....6455
Disassembled View....6455
Removal....6455
Installation....6459
Transmission Case and Transfer Case....6462
Major Component (MUA)....6462
Disassembly....6463
Reassembly....6466
Intermediate Plate with Gear Assembly, Detent, Shift Arm, and Interlock Pin (MUA)....6471
Disassembled View....6471
Disassembly....6472
Inspection and Repair....6473
Reassembly....6474
Reverse Gear and 5th Gear (MUA)....6475
Disassembled View....6475
Disassembly....6476
Inspection and Repair....6478
Reassembly....6478
Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft (MUA)....6484
Disassmebled View....6484
Disassembly....6485
Inspection and Repair....6486
Reassembly....6489
Main Data and Specifications....6495
Special Tools (MUA)....6499
7C CLUTCH....6501
Service Precaution....6501
General Description....6502
Diagnosis....6507
Clutch Assembly....6508
Clutch Assembly and Associated Parts....6508
Removal....6508
Inspection and Repair....6510
Installation....6514
Clutch Control....6516
Parts Location View....6516
Removal....6517
Inspection and Repair....6517
Installation....6517
Master Cylinder....6520
Disassembly....6520
Inspection and Repair....6520
Reassembly....6520
Slave Cylinder....6521
Disassembled View....6521
Disassembly....6521
Inspection and Repair....6521
Reassembly....6522
Damper Cylinder....6523
Disassembled View....6523
Disassembly....6523
Inspection and Repair....6523
Reassembly....6523
Main Data and Specifications....6524
Special Tools....6526
Sec.8 BODY AND ACCESSORIES....6527
8A LIGHTING SYSTEM....6527
Service Precaution....6528
Headlight Bulb....6529
Removal....6529
Installation....6529
Headlight Assembly....6529
Removal....6529
Installation....6529
Headlight Adjustment....6530
Fog Light Bulb....6531
Removal....6531
Installation....6531
Fog Light Assembly....6532
Removal....6532
Installation....6532
Fog Light Adjustment....6532
Clearance Light Bulb....6533
Removal....6533
Installation....6533
Front Combination Light Assembly....6534
Removal....6534
Installation....6534
Taillight Bulb....6534
Removal....6534
Installation....6534
License Plate Light Bulb....6535
Removal....6535
Installation....6535
Stoplight Bulb....6535
Removal and Installation....6535
High Mounted Stoplight Assembly....6536
Removal....6536
Installation....6536
High Mounted Stoplight Bulb....6536
Removal....6536
Installation....6536
Backup Light Bulb....6537
Removal....6537
Installation....6537
Front Turn Signal Light Bulb....6537
Removal....6537
Installation....6537
Side Turn Signal Light Bulb....6538
Removal....6538
Installation....6538
Rear Turn Signal Light Bulb....6538
Removal....6538
Installation....6538
Dome Light Bulb....6539
Removal....6539
Installation....6539
Courtesy Light Bulb....6539
Removal....6539
Installation....6539
Map Light Bulb....6540
Removal....6540
Installation....6540
Map Light Bulb (with Overhead Console)....6540
Removal....6540
Installation....6540
Luggage Room Light Bulb (4Door Model)....6541
Removal....6541
Installation....6541
HVAC Bezel Illumination Light Bulb....6541
Removal and Installation....6541
Shift Lever Illumination Light Bulb (A/T)....6542
Removal....6542
Ashtray Illumination Bulb....6542
Removal....6542
Installation....6542
Starter Switch....6542
Removal and Installation....6542
Lighting Switch (Combination Switch)....6543
Removal and Installation....6543
Dimmer・Passing Switch (Combination Switch)....6543
Removal and Installation....6543
Door Switch....6543
Removal....6543
Installation....6543
Rear Defogger Switch....6544
Removal....6544
Installation....6544
Key Remind Switch (Starter Switch)....6544
Removal and Installation....6544
Hazard Warning Light Switch....6544
Removal....6544
Installation....6544
Stoplight Switch....6545
Removal and Installation....6545
4WD Switch....6545
Removal....6545
Installation....6545
Fog Light Switch....6545
Removal....6545
Installation....6545
TOD Switch....6546
Removal....6546
Installation....6546
Cruise Main Switch....6546
Removal....6546
Installation....6546
Power/Winter Switch....6547
Removal....6547
Installation....6547
Intelligent Suspension Switch....6547
Removal....6547
Installation....6547
Illumination Controller....6548
Removal....6548
Installation....6548
Backup Light Switch (M/T)....6548
Removal....6548
Installation....6548
Turn Signal Light Switch (Combination Switch)....6548
Removal and Installation....6548
Light and Bulb Specifications....6549
8B WIPER / WASHER SYSTEM....6551
Service Precaution....6551
Windshield Wiper/Washer System....6552
General Description....6552
Windshield Wiper And Washer Switch....6552
Removal and Installation....6552
Windshield Wiper Motor....6552
Removal....6552
Installation....6552
Windshield Washer Motor....6553
Removal....6553
Installation....6553
Windshield Washer Spray Pattern....6554
Windshield Wiper Linkage....6555
Windshield Wiper Linkage and Associated Parts....6555
Removal....6555
Installation....6555
Windshield Wiper Arm/Blade....6556
Removal....6556
Installation....6556
Windshield Wiper Blade Rubber....6557
Removal....6557
Installation....6557
Rear Wiper/Washer System....6558
General Description....6558
Rear Wiper and Washer Switch....6558
Removal....6558
Installation....6558
Rear Wiper Motor....6559
Removal....6559
Installation....6559
Rear Washer Motor....6560
Removal....6560
Installation....6560
Alarm and Relay Control Unit....6560
Removal....6560
Installation....6560
Rear Wiper Arm/Blade....6561
Removal....6561
Rear Washer Nozzle....6561
Removal....6561
Installation....6561
Rear Washer Spray Pattern....6561
Rear Wiper Blade Rubber....6562
Removal....6562
Installation....6562
Main Data and Specifications....6563
8C ENTERTAINMENT....6564
Service Precaution....6564
Cigarette Lighter....6565
General Description....6565
Removal....6565
Installation....6565
Digital Clock....6565
Removal....6565
Installation....6566
Rod Type Antenna....6566
Removal....6566
Installation....6566
Radio....6567
Removal....6567
Installation....6567
Speaker....6568
Front Speaker....6568
Tweeter Assembly....6568
Rear Speaker....6568
Rear Door Speaker....6569
Accessory Socket....6569
Front Accessory Socket....6569
Rear Accessory Socket....6569
Horn....6570
Removal....6570
Installation....6570
8D WIRING SYSTEM....6571
Service Precaution....6572
General Description....6573
Notes for Working on Electrical Items....6573
Symbols and Abbreviations....6579
Parts for Electrical Circuit....6583
Reading the Circuit Diagram....6592
Main Data and Specifications....6595
Fuse, Fusible Link and Circuit Breaker Location....6595
Relay & Fuse Box (Engine Room)....6596
Relay & Fuse Box (Instrument panel)....6596
Fuse Block Circuit‐1....6597
Reference Table of Fuse, Fusible Link and Circuit Breaker....6602
Relay Location....6605
Diode Location....6607
Grounding Point....6609
Cable Harness Routing....6616
Start and Charging....6618
General Description....6618
Circuit Diagram-1....6619
Parts Location....6620
Powertrain Control Module (PCM)....6621
General Description....6621
Circuit Diagram-1....6622
Parts Location....6620
Headlight and Fog Light....6638
General Description....6638
Circuit Diagram-1....6639
Parts Location....6641
Diagnosis....6642
Clearance Light, Tail Light and License Plate Light....6646
General Description....6646
Circuit Diagram-1....6647
Parts Location....6649
Diagnosis....6650
Interior Illumination Light....6652
General Description....6652
Circuit Diagram-1....6653
Parts Location....6656
Diagnosis....6657
Turn Signal Light, Hazard Warning Light....6658
General Description....6658
Circuit Diagram-1....6659
Parts Location....6661
Diagnosis....6662
Stoplight....6665
General Description....6665
Circuit Diagram....6666
Parts Location....6667
Diagnosis....6668
Backup Light....6670
General Description....6670
Circuit Diagram....6671
Parts Location....6672
Diagnosis....6673
Horn....6675
General Description....6675
Circuit Diagram....6676
Parts Location....6677
Diagnosis....6678
Dome Light, Luggage Room Light, Courtesy Light, Map Light,Seat Belt Switch and Warning Buzzer....6679
General Description....6679
Circuit Diagram-1....6680
Parts Location....6682
Diagnosis....6683
Power Door Lock....6684
General Description....6684
Circuit Diagram-1....6685
Parts Location....6687
Diagnosis....6688
Power Window....6690
General Description....6690
Circuit Diagram-1....6691
Parts Location....6692
Diagnosis....6693
Anti‐Lock Brake System (ABS)....6698
General Description....6698
Circuit Diagram-1....6699
Parts Location....6701
A/T Shift Lock....6702
General Description....6702
Circuit Diagram-1....6703
Parts Location....6704
Windshield Wiper and Washer....6705
General Description....6705
Circuit Diagram....6706
Parts Location....6707
Diagnosis....6708
Rear Wiper/Washer....6713
General Description....6713
Circuit Diagram-1....6714
Parts Location....6716
Diagnosis....6717
Rear Defogger/Mirror Defogger....6721
General Description....6721
Circuit Diagram-1....6722
Parts Location....6724
Diagnosis....6725
Audio....6728
General Description....6728
Circuit Diagram-1....6729
Parts Location....6731
Cigarette Lighter, Digital Clock and Accessory Socket....6732
General Description....6732
Circuit Diagram....6733
Parts Location....6734
Diagnosis....6735
Power Door Mirror....6736
General Description....6736
Circuit Diagram-1....6737
Parts Location....6739
Diagnosis....6740
Keyless Entry....6742
General Description....6742
Circuit Diagram-1....6743
Parts Location....6745
Keyless Entry System....6746
Meter and Warning/Indicator Light....6747
General Description....6747
Circuit Diagram-1....6748
Parts Location....6755
Diagnosis....6756
Heater and Air Conditioning (Manual)....6760
General Description....6760
Circuit Diagram-1....6761
Parts Location....6763
Heater and Air Conditioning (Automatic)....6764
General Description....6764
Circuit Diagram-1....6765
Parts Location....6770
Sunroof....6771
General Description....6771
Circuit Diagram-1....6772
Parts Location....6773
Supplemental Restraint System (SRS)-Air Bag....6775
Supplemental Restraint System (SRS)-Air Bag....6775
General Description....6775
Circuit Diagram....6776
Parts Location....6777
Shift on the Fly System....6778
General Description....6778
Circuit Diagram-1....6779
Parts Location....6782
T.O.D.....6783
General Description....6783
Circuit Diagram-1....6784
Parts Location....6787
Alarme and Relay Control Unit....6788
Circuit Diagram-1....6788
Parts Location....6791
Intelligent Suspension....6792
General Description....6792
Circuit Diagram-1....6793
Parts Location....6797
Harness Connector Faces....6798
8E METER AND GAUGE....6816
Service Precaution....6816
Meter Assembly....6817
General Description....6817
Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination Lights....6817
Table for Meter/Gauge Connector Terminal Connections....6819
Removal....6821
Installation....6821
Warning Light Bulb, Indicator Light Bulb, Illumination Light Bulb,A/T Shift Indicator Light Bulb....6821
Removal....6821
Installation....6821
Vehicle Speed Sensor....6822
Removal....6822
Installation....6822
Fuel Tank Unit....6822
Removal and Installation....6822
Main Data and Specifications....6823
8F BODY STRUCTURE....6824
Service Precaution....6825
Frame....6825
General Description....6825
Frame Dimensions....6826
General Description (Bumper)....6827
Front Bumper....6827
Parts Location....6827
Removal....6828
Installation....6828
Front Bumper Slider Bracket....6829
Removal....6829
Installation....6829
Rear Bumper....6830
Parts Location....6830
Removal....6831
Installation....6831
Rear Bumper Slider....6832
Removal....6832
Installation....6832
General Description (Sheet Metal)....6833
Engine Hood....6833
Parts Location....6833
Removal....6834
Installation....6834
Engine Hood Lock....6836
Parts Location....6836
Removal....6836
Installation....6837
Radiator Grille....6838
Parts Location....6838
Removal....6838
Installation....6839
Front Fender Panel....6840
Parts Location....6840
Removal....6840
Installation....6841
Body Mounting....6843
Parts Location....6843
Tightening Torque....6843
Body Dimension....6844
Front Section....6844
Room Section (Front Side)....6847
Room Section (Rear Side)....6849
Rear Section....6851
Side Body Section (Front side)....6853
Side Body Section (Rear side)....6855
General Description (Body)....6857
Instrument Panel Assembly....6857
Parts Location....6857
Removal....6858
Installation....6860
Front Door Assembly....6861
Parts Location....6861
Removal....6861
Installation....6862
Rear Door Assembly....6863
Parts Location....6863
Removal....6863
Installation....6864
Front Window Regulator, Glass and Glass Run....6865
Parts Location....6865
Removal....6866
Installation....6867
Rear Window Regulator, Glass and Glass Run....6868
Parts Location....6868
Removal....6869
Installation....6870
Tailgate....6871
Parts Location....6871
Removal....6872
Installation....6873
Rear Hatchgate....6874
Parts Location....6874
Removal....6875
Installation....6875
Adjustment....6877
Spare Tire Carrier....6878
Parts Location....6878
Removal....6878
Installation....6878
Windshield....6879
Parts Location....6879
Removal....6879
Installation....6880
Rear Quarter Glass....6883
Parts Location....6883
Removal....6883
Installation....6884
Main Data and Specifications....6885
Special Tools....6888
8G SEATS....6889
Service Precaution....6889
Front Seat Assembly....6890
Front Seat Assembly and Associated Parts....6890
Removal....6890
Installation....6891
Rear Seat Assembly....6892
Rear Seat Cushion Assembly and Associated Parts....6892
Removal....6892
Installation....6893
Rear Seat Back Assembly and Associated Parts....6894
Removal....6894
Installation....6895
Main Data and Specifications....6896
Torque Specifications....6896
8H SECURITY AND LOCKS....6897
Service Precaution....6897
Front Door Lock Assembly....6898
Front Door Lock Assembly and Associated Parts....6898
Removal....6899
Installation....6900
Front Outside Handle....6901
Front Outside Handle and Associated Parts....6901
Removal....6901
Installation....6901
Rear Door Lock Assembly....6902
Rear Door Lock Assembly and Associated Parts....6902
Removal....6903
Installation....6903
Rear Outside Handle....6904
Rear Outside Handle and Associated Parts....6904
Removal....6904
Installation....6904
Tailgate Lock and Hatchgate Lock....6905
Tailgate Lock, Hatchgate Lock and Associated Parts....6905
Removal....6906
Installation....6907
Fuel Filler Door Lock....6908
Fuel Filler Door Lock and Associated Parts....6908
Removal....6908
Installation....6909
Key....6910
Key Coding....6910
Key Styles....6910
Power Door Lock System....6911
General Description....6911
Door Lock Key Switch....6911
Front Door Lock Actuator....6911
Rear Door Lock Actuator....6911
Tailgate Lock Actuator....6911
Fuel Filler Door Lock Actuator....6911
Keyless Entry System....6912
General Description....6912
Keyless Entry Control Unit....6912
Keyless Entry Control Unit/Transmitter Replacement....6912
Main Data and Specifications....6913
8I SUNROOF/CONVERTIBLE TOP....6914
Service Precaution....6914
Sunroof Glass....6915
Sunroof Glass and Associated Parts....6915
Removal....6915
Installation....6916
Sunroof Deflector....6917
Removal....6917
Installation....6917
Sunshade....6918
Disassembled View....6918
Removal....6918
Installation....6919
Sunroof Frame Complete Assembly....6920
Sunroof Frame Complete Assembly and Associated Parts....6920
Removal....6920
Installation....6921
Sunroof Switch....6921
Removal....6921
Installation....6921
Sunroof Control Unit....6922
Removal....6922
Installation....6922
Sunroof Motor....6922
Removal....6922
Installation....6922
Main Data and Specifications....6923
8J EXTERIOR / INTERIOR TRIM....6924
Service Precaution....6925
Consoles....6926
Consoles and Associated Parts....6926
Removal....6926
Installation....6926
Front Door Trim Panel....6927
Front Door Trim Panel and Associated Parts....6927
Removal....6928
Installation....6928
Rear Door Trim Panel....6929
Rear Door Trim Panel and Associated Parts....6929
Removal....6930
Installation....6930
Door Mirror Assembly....6931
Removal....6931
Installation....6931
Mirror Replacement....6931
Interior Mirror Assembly....6932
Removal....6932
Installation....6932
Interior Trim Panels....6933
Interior Trim Panels and Associated Parts....6933
Removal....6933
Installation....6935
Overhead Console....6936
Parts Location....6936
Removal....6936
Installation....6936
Headlining....6937
Parts Location....6937
Removal....6937
Installation....6938
Wheel Arch Protector....6939
Wheel Arch Protector and Associated Parts....6939
Removal....6939
Installation....6939
Wheel Arch Moulding....6940
Wheel Arch Moulding and Associated Parts....6940
Removal....6940
Installation....6941
Fuel Filler Door....6942
Parts Location....6942
Removal....6942
Installation....6942
Roof Rail....6943
Parts Location....6943
Removal....6943
Installation....6943
Power Door Mirror System....6944
General Description....6944
Door Mirror Switch....6944
Power Window System....6945
General Description....6945
Power Window Switch Driver Seat Side....6945
Power Window Motor....6946
Main Data and Specifications....6948
Sec.9 RESTRAINTS....6949
9A SEAT BELT SYSTEM....6949
Service Precaution....6949
Front Seat Belt....6950
Front Seat Belt and Associated Parts....6950
Removal....6950
Inspection....6950
Installation....6951
Front Seat Belt....6952
Front Seat Belt and Associated Parts....6952
Removal....6952
Inspection....6953
Installation....6954
Front Seat Buckle Assembly....6955
Removal....6955
Installation....6955
Rear Center Seat Belt / Buckle Assembly....6956
Rear Center Seat Belt / Buckle Assembly and Associated Parts....6956
Removal....6956
Installation....6956
Child Seat Tether Anchor Bracket (Child Restraint)....6957
General Description....6957
Child Seat Tether Anchor Bracket and Associated Parts....6957
Installation....6957
Main Data and Specifications....6958
9J SEAT BELT SYSTEM....6960
Service Precaution....6960
General Description....6961
SRS Component and Wiring Location View....6963
Component Description....6963
Definition....6966
Diagnosis....6967
SRS Connector Body Face Views....6968
Repairs and Inspections Required After an Accident....6968
On–Vehicle Service....6969
Air Bag Assembly Handling /Shipping / Scrapping....6970
Special Tools....6986
Service Precaution....6992
Sensing and Diagnostic Module (SDM)....6994
Service Precautions....6994
Removal....6994
Installation....6994
Driver Air Bag Assembly....6996
Service Precautions....6996
Removal....6996
Installation....6996
Steering Wheel....6997
Service Precautions....6997
Removal....6997
Installation....6998
SRS Coil Assembly....6999
Service Precaution....6999
Removal....6999
How to Disconnect the horn terminal....7001
How to Connect Horn Terminal....7001
Installation....7002
Steering Column....7004
Service Precaution....7004
Removal....7004
Installation....7006
Passenger Air Bag Assembly....7008
Service Precaution....7008
Removal....7008
Installation....7008
Main Data and Specifications....7009
SRS Air Bag System Inspection Standards For Repair....7010
9J1 SRS CONTROL SYSTEM....7011
Service Precaution....7011
Diagnostic Information....7012
Parts For Electrical Circuit....7014
System Schematic....7015
SRS Diagnostic System Check....7015
Chart A SDM Integrity Check....7019
Chart B “AIR BAG" Warning Lamp Comes “ON" Steady....7021
Chart C “AIR BAG" Warning Lamp Does Not Comes “ON" Steady....7023
DTC 15 Passenger Deployment Loop Resistance High....7026
DTC 16 Passenger Deployment Loop Resistance Low....7029
DTC 17 Passenger Deployment Loop Open....7032
DTC 18 Passenger Deployment Loop Short To Ground....7035
DTC 19 Passenger Deployment Loop Short To Voltage....7038
DTC 21 Driver Deployment Loop Resistance High....7041
DTC 22 Driver Deployment Loop Resistance Low....7044
DTC 24 Driver Deployment Loop Short To Ground....7047
DTC 25 Driver Deployment Loop Short To Voltage....7050
DTC 26 Driver Deployment Loop Open....7054
DTC 51 Deployment Event Commanded....7057
DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy Reserves Out Of Range....7059
DTC 61 Warning Lamp Circuit Failure....7062
DTC 71 Internal SDM Fault....7064
Sec.10 CONTROL SYSTEM....7066
10A CRUISE CONTROL SYSTEM....7066
Service Precaution....7066
General Description....7066
Brake Switch....7067
Removal and Installation....7067
Adjustment....7067
Clutch Switch....7068
Removal and Installation....7068
Adjustment....7068
Powertrain Control Module (PCM)....7068
Removal and Installation....7068
Mode Switch....7068
Removal and Installation....7068
Cruise Control Main Switch....7069
Removal....7069
Installation....7069
Cruise Control Switch (Combination Switch)....7069
Removal and Installation....7069
Diagnosis....7070
Isuzu Frontera Service Manual 1999-2001
