Isuzu Trooper All Models Service Repair Manual
Complete repair service manual with electrical wiring diagrams for Isuzu Trooper all models, with all the shop information to maintain, diagnose, repair, and service like professional mechanics.
Isuzu Trooper 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.
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Isuzu UX Trooper Workshop Manual.pdf
Isuzu UBS Trooper Workshop Manual.pdf
PRODUCT DETAILS:
Total Pages: 17,587 pages
File Format: PDF (Windows & Mac & Linux)
Language: English
'95 UX Trooper Workshop Manual....2
ETM....3
Workshop Manual....280
'98-'02 UBS Trooper Workshop Manual....2208
ECU in Japanese....2209
EXP UBS....2220
TOP....0
EXP UBS....2221
1998/1999 MODEL....0
UBS....2222
Sec.0 GENERAL INFORMATION....2234
0A GENERAL INFORMATION....2234
GENERAL REPAIR INSTRUCTIONS....2235
HOW TO USE THIS MANUAL....2236
IDENTIFICATION....2239
LIFTING INSTRUCTIONS....2241
TORQUE SPECIFICATIONS....2243
RECOMMENDED LIQUID GASKET....2244
RECOMMENDED THREAD LOCKING AGENTS....2244
ABBREVIATIONS CHARTS....2245
0B MAINTENANCE AND LUBRICATION....2247
MAINTENANCE SCHEDULE....2248
RECOMMENDED FLUIDS, LUBRICANTS AND FUELS....2253
OIL VISCOSITY CHART....2256
Sec.1 SERVICE INFORMATION....2259
00 SERVICE INFORMATION....2259
TROUBLESHOOTING....2261
CIRCUIT DIAGRAM....2262
HEATING CYCLE TROUBLESHOOTING....2274
FAN CONTROL KNOB (FAN SWITCH)....2275
BLOWER MOTOR DOES NOT RUN....2276
BLOWER MOTOR DOES NOT RUN IN CERTAIN POSITION....2277
BLOWER MOTOR DOES NOT STOP AT "OFF" POSITION....2277
CERAMIC HEATER....2278
CERAMIC HEATER DOES NOT OPERATE....2279
CERAMIC HEATER DOES NOT STOP....2280
AIR CONDITIONING CYCLE TROUBLESHOOTING....2281
CHECKING REFRIGERANT SYSTEM WITH MANIFOLD GAUGE....2282
MAGNETIC CLUTCH....2285
6VD1/6VE1 ENGINE....2285
4JG2 ENGINE....2289
4JX1 ENGINE....2292
CONDENSER FAN....2295
CONDENSER FAN DOES NOT RUN....2296
CONDENSER FAN DOES NOT STOP....2297
COMPRESSOR TROUBLESHOOTING....2298
INDIVIDUAL INSPECTION....2299
MAIN DATA AND SPECIFICATIONS....2303
FIXING TORQUE....2306
SPECIAL TOOLS....2310
1A HEATING AND VENTILATION....2315
GENERAL DESCRIPTION....2316
HEATER....2316
CONTROL LEVER ASSEMBLY....2317
VENTILATION....2317
AIR SELECT KNOB....2318
AIR SOURCE SELECT LEVER....2318
FAN CONTROL KNOB....2318
TEMPERATURE CONTROL KNOB....2318
CERAMIC HEATER....2319
ON-VEHICLE SERVICE....2320
HEATER UNIT....2320
HEATER CORE AND/OR MODE DOOR....2322
HEATER MODE CONTROL LINK UNIT....2324
HEATER TEMPERATURE CONTROL LINK UNIT....2326
BLOWER ASSEMBLY....2328
BLOWER LINK UNIT AND/OR MODE DOOR....2330
BLOWER MOTOR....2332
REAR HEATER DUCT, DEFROSTER NOZZLE AND VENTILATION DUCT....2334
CENTER AND/OR SIDE VENT....2336
CONTROL LEVER ASSEMBLY AND/OR CONTROL CABLES....2338
CONTROL PANEL ILLUMINATION BULB....2341
RESISTOR....2342
CERAMIC HEATER AND/OR FULL HOT SWITCH....2344
1B AIR CONDITIONING....2346
GENERAL DESCRIPTION....2348
AIR CONDITIONING REFRIGERANT CYCLE CONSTRUCTION....2348
COMPRESSOR....2349
MAGNETIC CLUTCH....2350
DUAL PRESSURE SWITCH....2351
TRIPLE PRESSURE SWITCH....2351
EXPANSION VALVE....2351
EVAPORATOR....2352
ELECTRONIC THERMOSTAT....2352
REFRIGERANT LINE....2352
SERVICE CHARGE VALVES....2352
AIR CONDITIONING PARTS....2353
ON-VEHICLE SERVICE....2358
PRECAUTIONS FOR REPLACEMENT OR REPAIR OF AIR CONDITIONING PARTS....2358
Compressor Assembly and Associated Parts....2368
CONDENSER ASSEMBLY (LHD V6 WITHOUT CONDENSER FAN)....2378
CONDENSER FAN MOTOR....2380
RECEIVER/DRIER....2382
PRESSURE SWITCH....2384
EVAPORATOR ASSEMBLY....2387
EVAPORATOR CORE AND/OR EXPANSION VALVE....2389
ELECTRONIC THERMOSTAT....2392
A/C SWITCH AND ILLUMINATION BULB....2393
REFRIGERANT LINE....2394
REAR COOLER PARTS....2396
FULL AUTOMATIC AIR CONDITIONING SYSTEM....2405
GENERAL DESCRIPTION....2405
Full Automatic Air Conditioner Parts Configuration....2405
CIRCUIT DIAGRAM....2407
FUNCTIONS AND FEATURES....2419
FULL AUTOMATIC AIR CONDITIONER BLOCK DIAGRAM....2420
AIR CONDITIONING PARTS....2421
Control Panel Layout....2425
Air Control Functions....2426
OPERATION AND FUNCTIONS OF CONTROL PANEL SWITCHES....2427
OVERVIEW OF CONSTRUCTION, MOVEMENT AND CONTROL OF MAJOR PARTS OF FULL AUTOMATIC AIR CONDITIONER SYSTEM....2429
OVERVIEW OF AUTOMATIC CONTROL OF FULL AUTOMATIC AIR CONDITIONER....2433
TROUBLESHOOTING....2437
Troubleshooting, Its Overview and Procedures....2437
Performance and Movement checklist for Automatic Air Conditioner Related Parts....2440
TROUBLESHOOTING WITH SELF-DIAGNOSIS FUNCTION....2442
INSPECTION BY FAILED LOCATION....2445
Inspection of the Sensors....2445
Inspection of the Intake Actuator System....2449
Inspection of the Mix Actuator System....2452
Inspection of the Mode Actuator System....2455
Inspection of the Fan Motor System....2458
Inspection of the Magnet Clutch System....2463
Inspection of the Air Conditioner Room Temperature Setup System....2468
INDIVIDUAL INSPECTION....2469
ON-VEHICLE SERVICE....2471
Power Transistor....2471
Automatic Heater/Air Conditioner Control Unit....2471
In Car Sensor....2472
Ambient Sensor....2472
Sun Sensor....2473
Electronic Thermostat....2473
Mode Actuator....2474
MIX Actuator....2474
Intake Actuator....2475
1D COMPRESSOR OVERHAUL....2476
GENERAL DESCRIPTION....2477
GENERAL INFORMATION....2479
COMPRESSOR OIL....2479
SERVICE PROCEDURE....2481
DKV-14D TYPE COMPRESSOR....2481
DKS-15CH TYPE COMPRESSOR....2485
HD6 TYPE COMPRESSOR....2493
Sec.2 SERVICE INFORMATION....2502
00 SERVICE INFORMATION....2502
TROUBLESHOOTING....2504
GENERAL INFORMATION....2505
GENERAL TROUBLESHOOTING....2505
POWER STEERING SYSTEM....2508
POWER STEERING PUMP....2509
STEERING COLUMN....2510
MAIN DATA AND SPECIFICATIONS....2512
SERVICE STANDARD....2513
SERVICING....2514
FIXING TORQUE....2516
SPECIAL TOOLS....2520
2A FRONT END ALIGNMENT....2522
GENERAL DESCRIPTION....2523
DEFINITION OF TERMS....2523
ON-VEHICLE SERVICE....2524
INSPECTION....2524
TRIM HEIGHT ADJUSTMENT....2524
CASTER ADJUSTMENT....2525
CAMBER ADJUSTMENT....2525
TOE-IN ADJUSTMENT....2526
MAXIMUM STEERING ANGLE ADJUSTMENT....2526
Sec.3 SUSPENSION....2608
3C FRONT SUSPENSION....2608
GENERAL DESCRIPTION....2609
ON-VEHICLE SERVICE....2610
SHOCK ABSORBER....2610
STABILIZER BAR....2612
TORSION BAR....2614
KNUCKLE....2617
UPPER CONTROL ARM....2621
LOWER CONTROL ARM....2625
UPPER BALL JOINT....2629
LOWER BALL JOINT....2632
3D REAR SUSPENSION; COIL SPRING....2635
GENERAL DESCRIPTION....2636
ON-VEHICLE SERVICE....2637
COIL SPRING....2637
SHOCK ABSORBER....2640
TRAILING LINK....2642
CENTER LINK....2644
LATERAL ROD....2646
STABILIZER BAR....2649
3E WHEELS AND TIRES....2651
GENERAL DESCRIPTION....2652
ON-VEHICLE SERVICE....2653
WHEELS....2653
UNIT REPAIR....2654
TIRES....2654
WHEELS....2655
GENERAL BALANCE PROCEDURE....2655
BALANCING WHEEL AND TIRE....2656
Sec.4 DRIVELINE/AXLE....2657
4A1 DIFFERENTIAL (FRONT)....2657
Service Precaution....2657
Front Drive Axle....2658
Diagnosis....2658
Pinion Shaft Oil Seal....2659
Pinion Shaft Oil Seal and Associated Parts....2659
Removal....2659
Inspection and Repair....2660
Installation....2660
Front Drive Axle Assembly....2661
Front Drive Axle Assembly and Associated Parts....2661
Removal....2661
Installation....2663
Differential Assembly....2665
Disassembled View....2665
Disassembly....2665
Reassembly....2668
Differential Cage Assembly....2677
Disassembled View....2677
Disassembly....2677
Inspection and Repair....2678
Reassembly....2679
Main Data and Specifications....2681
Special Tools....2684
4A2A DIFFERENTIAL (Rear 220mm)....2687
Service Precaution....2687
General Description....2688
Diagnosis....2689
Axle Housing....2690
Axle Housing and Associated Parts....2690
Removal....2690
Oil Seal Replacement....2691
Installation....2691
Pinion Oil Seal....2692
Pinion Oil Seal and Associated Parts....2692
Removal....2692
Inspection and Repair....2693
Installation....2693
Differential Assembly....2694
Differential Assembly and Associated Parts....2694
Removal....2694
Installation....2695
Disassembled View....2696
Disassembly....2697
Reassembly....2699
Differential Cage Assembly....2707
Disassembled View....2707
Disassembly....2707
Inspection and Repair....2708
Reassembly....2709
Limited Slip Differential....2711
Disassembled View....2711
Disassembly....2712
Inspection and Repair....2712
Reassembly....2714
Main Data and Specifications....2718
Special Tools....2720
4A2B DIFFERENTIAL (REAR 244mm)....2723
Service Precaution....2723
General Description....2724
Diagnosis....2725
Axle Housing....2726
Axle Housing and Associated Parts....2726
Removal....2726
Oil Seal Replacement....2727
Installation....2727
Pinion Oil Seal....2728
Pinion Oil Seal and Associated Parts....2728
Removal....2728
Inspection and Repair....2729
Installation....2729
Differential Assembly....2730
Differential Assembly and Associated Parts....2730
Removal....2730
Installation....2731
Disassembled View....2732
Disassembly....2733
Reassembly....2735
Differential Cage Assembly....2742
Disassembled View....2742
Disassembly....2743
Inspection and Repair....2743
Reassembly....2743
Locking Differential Assembly....2745
Disassembled View....2745
Disassembly....2745
Inspection and Repair....2747
Reassembly....2747
Main Data and Specifications....2749
Special Tools....2751
4B1 DRIVELINE CONTROL SYSTEM (SHIFT ON THE FLY)....2753
Service Precaution....2753
Shift on the Fly System (Lever Type)....2754
Outline of Shift on the Fly System (Lever Type)....2754
Shift on the Fly Vacuum Piping and Electric Equipment (For Lever Control Type)....2755
Vacuum Piping Diagram....2755
Inspection and Repair....2756
Shift on the Fly System (Push Button Type)....2759
Outline of Shift on the Fly System (Push Button Type)....2759
Functions of Indicator Lamp....2763
Diagnosis....2763
Front Axle Diagnosis....2782
Shift on the Fly Vacuum Piping and Electric Equipment (For Push Button Type)....2784
Vacuum Piping Diagram....2784
Inspection and Repair....2785
4WD Control Unit (For Push Button Type)....2788
4WD Control Unit Associated Parts....2788
Removal....2789
Installation....2789
4B2 DRIVELINE CONTROL SYSTEM (TOD)....2791
Service Precaution....2791
General Description....2792
System Components....2794
Parts Location....2794
Functions of Indicator Lamp....2798
Diagnosis....2802
Basic Diagnostic Flow Chart....2806
Parts Location....2807
Circuit Diagram....2808
Connector List....2811
Checking Failed Pin....2813
Checking Failed TOD Control Unit Pin....2816
Diagnostic Trouble Codes....2820
Diagnosis from Trouble Codes....2821
Trouble Diagnosis Depending on The Status of TOD Indicator....2848
Diagnosis from Symptom....2876
4C DRIVE SHAFT SYSTEM....2886
Service Precaution....2887
General Description....2887
Diagnosis....2888
Rear Axle Shaft....2889
Rear Axle Shaft and Associated Parts....2889
Removal....2889
Inspection and Repair....2890
Oil Seal Replacement....2891
Installation....2891
Special Tools....2893
Front Hub and Disc (with Shift on the Fly)....2894
Disassembled View....2894
Disassembly....2894
Inspection and Repair....2895
Reassembly....2896
Front Hub and Disc with Manual Locking Hub....2899
Disassembled View....2899
Disassembly....2899
Inspection and Repair....2901
Reassembly....2901
Main Data and Specifications....2905
Special Tools....2906
Front Drive Shaft Joint....2907
Front Drive Shaft Joints Replacement....2907
Front Axle Drive Shaft....2908
Front Axle Drive Shaft and Associated Parts....2908
Disassembly....2909
Inspection and Repair....2910
Bushing Replacement....2910
Reassembly....2911
Shift On The Fly System....2913
Shift On The Fly System and Associated Parts....2913
Disassembly....2913
Inspection and Repair....2915
Main Data and Specifications....2920
Special Tools....2921
Front Propeller Shaft....2922
General Description....2922
Front Propeller Shaft and Associated Parts....2923
Removal....2923
Installation....2924
Disassembly (Except TOD 4×4)....2925
Universal Joint Disassembly....2926
Inspection and Repair....2927
Universal Joint Reassembly....2930
Reassembly (Except TOD 4×4)....2931
Main Data and Specifications....2932
Rear Propeller Shaft....2933
General Description....2933
Rear Propeller Shaft and Associated Parts....2933
Removal....2934
Installation....2934
Disassembly....2935
Universal Joint Disassembly....2936
Inspection and Repair....2937
Universal Joint Reassembly....2938
Reassembly....2939
Main Data and Specifications....2940
4D1 TRANSFER CASE (STANDARD TYPE)....2941
Service Precaution....2941
General Description....2942
Transfer Rear Oil Seal....2948
Removal....2948
Installation....2948
Transfer Case Assembly....2949
Removal....2949
Installation....2950
Transfer Rear Cover Assembly (4WD Switch Model)....2951
Transfer Rear Cover Assembly and Associated Parts....2951
Removal....2952
Installation....2953
Disassembly....2956
Inspection and Repair....2957
Reassembly....2957
Transfer Rear Cover Assembly (Except 4WD Switch Model)....2959
Transfer Rear Cover Assembly and Associated Parts....2959
Removal....2960
Installation....2960
Disassembly....2963
Inspection and Repair....2964
Reassembly....2964
Detent, Shift Arm, and Interlock Pin....2966
Disassembled View....2966
Disassembly....2966
Inspection and Repair....2968
Reassembly....2968
Transfer Case Assembly....2970
Disassembled View....2970
Disassembly....2971
Inspection and Repair....2973
Reassembly....2977
Main Data and Specifications....2983
Special Tools....2986
4D2 TRANSFER CASE (TOD)....2987
Service Precaution....2987
Transfer Case Assembly....2988
Removal....2988
Installation....2989
Transfer Rear Oil Seal....2991
Transfer Rear Oil Seal and Associated Parts....2991
Removal....2991
Installation....2991
TOD ECU....2993
Removal....2993
Installation....2993
Unit Repair....2994
Inspection....2994
Transfer Case....2995
Disassembled View....2995
Disassembly....2995
Reassembly....2996
Transfer Cover Assembly....2998
Disassembled View....2998
Disassembly....2998
Reassembly....3000
Transfer Case Assembly Clutch Pack and Clutch Cam....3002
Disassembled View....3002
Disassembly....3002
Sprocket and Mechanical Lock....3004
Disassembled View....3004
Disassembly....3004
Output Shafts and Shift Control Shaft....3006
Disassembled View....3006
Disassembly....3007
Transfer Case....3009
Disassembled View....3009
Disassembly....3010
Inspection and Repair....3012
Transfer Case....3016
Disassembled View....3016
Reassembly....3016
Output Shafts and Shift Control Shaft....3020
Disassembled View....3020
Reassembly....3020
Sprocket and Mechanical Lock....3023
Disassembled View....3023
Reassembly....3023
Clutch Pack and Clutch Cam....3025
Disassembled View....3025
Reassembly....3025
Main Data and Specifications....3027
Special Tools....3029
Sec.5 BRAKES....3030
5A BRAKE CONTROL SYSTEM....3030
Service Precaution....3031
General Description....3032
System Components....3032
Electronic Hydraulic Control Unit (EHCU)....3032
ABS Warning Light....3033
Wheel Speed Sensor....3033
G-Sensor....3033
Normal and Anti-lock Braking....3033
Brake Pedal Travel....3033
Acronyms and Abbreviations....3033
General Diagnosis....3034
General Information....3034
ABS Service Precautions....3034
Computer System Service Precautions....3034
General Service Precautions....3034
Note on Intermittents....3034
Test Driving ABS Complaint Vehicles....3035
“ABS” Warning Light....3035
Normal Operation....3035
Basic Diagnostic Flow Chart....3035
Basic Inspection Procedure....3036
Tech 2 Scan Tool....3037
Getting Started....3038
Operating Procedure....3039
Data List....3040
EHCU Connector Pin-out Checks....3041
Circuit Diagram (LHD model / 6VD1 and 4JG2)....3042
Circuit Diagram (LHD model / 4JG2)....3043
Circuit Diagram (LHD model / 4JG2)....3044
Circuit Diagram (LHD model / 6VD1)....3045
Circuit Diagram (LHD model / 6VD1)....3046
Connector List (LHD model)....3047
Part Location (LHD model)....3049
Circuit Diagram (RHD model / 6VD1 and 4JG2)....3050
Circuit Diagram (RHD model / 4JG2)....3051
Circuit Diagram (RHD model / 4JG2)....3052
Circuit Diagram (RHD model / 6VD1)....3053
Circuit Diagram (RHD model / 6VD1)....3054
Circuit Diagram (RHD model / 6VE1 and 4JX1)....3055
Circuit Diagram (RHD model / 4JX1)....3056
Circuit Diagram (RHD model / 4JX1)....3057
Circuit Diagram (RHD model / 6VE1)....3058
Circuit Diagram (RHD model / 6VE1)....3059
Connector List (RHD model)....3060
Part Location (RHD model)....3063
Symptom Diagnosis....3064
Chart A–1 ABS Works Frequently But Vehicle Does Not Decelerate....3064
Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)....3065
Chart A-2 Uneven Braking Occurs While ABS Works....3065
Chart A-3, TA-3 The Wheels Are Locked....3065
Chart A-4 Brake Pedal Feed Is Abnormal....3066
Chart A-5, TA-5 Braking Sound (From EHCU) Is Heard While Not Braking....3067
Diagnostic Trouble Codes....3068
Diagnosis By “ABS” Warning Light Illumination Pattern....3069
Diagnostic Trouble Codes (DTCs)....3069
Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated.....3072
Chart B-2 EHCU Abnormality (DTC 14)....3072
Chart B-3 Power Voltage Drop (DTC 15)....3073
Chart B-4 CLASS-2 Communication Line Abnormality (DTC 16)....3073
Chart B-5 G-Sensor Circuit (DTC 21)....3074
Chart B-6 Abnormal Transmission Input (DTC 23)....3075
Chart B-7 Transfer Monitor (DTC 24)....3076
Chart B-8 EHCU Pump Motor And Motor Relay Circuit (DTC 32)....3076
Chart B-9 EHCU Pump Valve And Valve Relay Circuit (DTC 35)....3076
Chart B-10 FL Isolation Solenoid Valve Abnormality (DTC 41)....3077
Chart B-11 FL Dump Solenoid Valve Abnormality (DTC 42)....3077
Chart B-12 FR Isolation Solenoid Valve Abnormality (DTC 43)....3077
Chart B-13 FR Dump Solenoid Valve Abnormality (DTC 44)....3078
Chart B-14 Rear Isolation Solenoid Valve Abnormality (DTC 45)....3078
Chart B-15 Rear Dump Solenoid Valve Abnormality (DTC 46)....3078
Chart B-16 FL Speed Sensor Disconnection (DTC 51)....3079
Chart B-17 FR Speed Sensor Disconnection (DTC 52)....3079
Chart B-18 RL Speed Sensor Disconnection (DTC 53)....3080
Chart B-19 RR Speed Sensor Disconnection (DTC 54)....3080
Chart B-20 FL Speed Sensor Short Circuit (DTC 61)....3081
Chart B-21 FR Speed Sensor Short Circuit (DTC 62)....3082
Chart B-22 RL Speed Sensor Short Circuit (DTC 63)....3083
Chart B-23 RR Speed Sensor Short Circuit (DTC 64)....3084
Chart B-24 Sensor Signal Input Abnormality (DTC 65)....3085
Sensor Signal Abnormality Criteria using TECH 2....3085
Unit Inspection Procedure....3086
Chart C-1-1 FL Sensor Output Inspection Procedure....3086
Chart C-1-2 FR Sensor Output Inspection Procedure....3087
Chart C-1-3 RL Sensor Output Inspection Procedure....3087
Chart C-1-4 RR Sensor Output Inspection Procedure....3088
Chart TC-1 Sensor Output Inspection Procedure (Use TECH 2)....3088
Chart C-2 Transmission Input Inspection Procedure....3089
Chart TC-2 Transmission Input Inspection Procedure (Use TECH 2)....3090
Special Tools....3091
5B ANTI-LOCK BRAKE SYSTEM....3092
Service Precaution....3092
Electronic Hydraulic Control Unit....3093
Electronic Hydraulic Control Unit and Associated Parts....3093
Removal....3093
Installation....3093
G-Sensor....3094
Removal....3094
Inspection and Repair....3094
Installation....3094
Front Wheel Speed Sensor....3095
Front Wheel Speed Sensor and Associated Parts....3095
Removal....3095
Inspection and Repair....3096
Installation....3096
Rear Wheel Speed Sensor....3097
Rear Wheel Speed Sensor and Associated Parts....3097
Removal....3097
Inspection and Repair....3097
Installation....3097
5C POWER ASSISTED BRAKE SYSTEM....3098
SERVICE PRECAUTION....3099
BRAKE SYSTEM DIAGNOSIS....3100
TROUBLESHOOTING....3102
MAIN DATA AND SPECIFICATIONS....3104
SERVICE STANDARD....3105
SERVICING....3106
FIXING TORQUE....3115
SPECIAL TOOLS....3118
GENERAL DESCRIPTION....3119
MASTER CYLINDER....3119
VACUUM BOOSTER....3120
DISC BRAKES....3121
ON-VEHICLE SERVICE....3122
BRAKE HOSE REPLACEMENT....3122
BRAKE PIPE REPLACEMENT....3124
P & B VALVE....3125
P & B VALVE REPLACEMENT....3126
LOAD SENSING PROPORTIONING VALVE (LSPV)....3127
BRAKE PEDAL REPLACEMENT....3131
STOPLIGHT SWITCH REPLACEMENT....3133
FLUID RESERVOIR TANK....3135
MASATER CYLINDER ASSEMBLY....3136
VACUUM BOOSTER ASSEMBLY....3138
EXTERIOR COMPONENTS....3141
FRONT DISC BRAKE....3144
BRAKE PADS REPLACEMENT....3144
CALIPER REPLACEMENT....3147
REBUILDING THE CALIPER....3150
REAR DISC BRAKE....3153
BRAKE PADS REPLACEMENT....3153
CALIPER REPLACEMENT....3156
REBUILDING THE CALIPER....3159
UNIT REPAIR....3162
MASTER CYLINDER....3162
VACUUM BOOSTER....3164
5D PARKING BRAKES....3165
SERVICE PRECAUTION....3165
MAIN DATA AND SPECIFICATIONS....3166
SERVICE STANDARD....3166
SERVICING....3167
FIXING TORQUE....3169
GENERAL DESCRIPTION....3170
ON-VEHICLE SERVICE....3171
PARKING BRAKE LEVER REPLACEMENT....3171
PARKING BRAKE CABLE....3173
Sec.6 ENGINE(6VD1/6VE1)....3176
6A ENGINE MECHANICAL....3176
Service Precaution....3177
General Description....3178
Engine Diagnosis....3179
Cylinder Head Cover LH....3193
Removal....3193
Installation....3194
Cylinder Head Cover RH....3196
Removal....3196
Installation....3197
Common Chamber....3199
Removal....3199
Installation....3199
Exhaust Manifold LH....3201
Removal....3201
Installation....3201
Exhaust Manifold RH....3202
Removal....3202
Installation....3202
Crankshaft Pulley....3203
Removal....3203
Installation....3203
Timing Belt....3204
Removal....3204
Installation....3205
Camshaft....3208
Removal....3208
Installation....3208
Cylinder Head....3212
Removal....3212
Installation....3212
Valve Stem Oil Controller , Valve Spring and Valve Guide....3214
Removal....3214
Installation....3214
Piston, Piston Ring and Connecting Rod....3215
Removal....3215
Installation....3216
Crankshaft and Main Bearings....3217
Removal....3217
Installation....3218
Rear Oil Seal....3222
Removal....3222
Installation....3222
Engine Assembly....3223
Removal....3223
Installation....3223
Cylinder Head....3227
Cylinder Head and Associated Parts....3227
Disassembly....3227
Clean....3228
Inspection and Repair....3228
Reassembly....3228
Valve Spring, Oil Controller, Valve, Valve Guide....3231
Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts....3231
Disassembly....3231
Inspection and Repair....3232
Reassembly....3235
Valve Clearance Adjustments....3236
Camshaft....3238
Camshaft and Associated Parts....3238
Disassembly....3238
Inspection and Repair....3239
Reassembly....3241
Crankshaft....3244
Crankshaft and Associated Parts....3244
Disassembly....3244
Inspection and Repair....3245
Inspection and Repair....3246
Reassembly....3248
Piston and Connecting Rod....3252
Piston, Connecting Rod and Associate Parts....3252
Disassembly....3252
Inspection and Repair....3253
Reassembly....3257
Cylinder Block....3260
Cylinder Block and Associated Parts....3260
Disassembly....3260
Inspection and Repair....3261
Reassembly....3262
Main Data and Specification....3265
Special Tool....3271
6B ENGINE COOLING....3273
Service Precaution....3273
General Description....3274
Diagnosis....3277
Draining and Refilling Cooling System....3278
Water Pump....3279
Water Pump and Associated Parts....3279
Removal....3279
Inspection....3279
Installation....3279
Thermostat....3280
Thermostat and Associated Parts....3280
Removal....3280
Inspection....3280
Installation....3280
Radiator....3281
Radiator and Associated Parts....3281
Removal....3281
Inspection....3282
Installation....3283
Drive Belt and Cooling Fan....3284
Drive Belt and Associated Parts....3284
Inspection....3284
Installation....3284
Main Data and Specifications....3285
Special Tool....3286
6C ENGINE FUEL....3287
Service Precaution....3287
General Description....3288
Fuel Metering....3289
Fuel Filter....3290
Fuel Filter and Associated Parts....3290
Removal....3290
Inspection....3290
Installation....3291
Inspection....3291
In–Tank Fuel Filter....3291
Fuel Pump Flow Test....3291
Fuel Pump....3292
Fuel Pump and Associated Parts....3292
Removal....3292
Installation....3292
Fuel Pump Relay....3293
General Description....3293
Fuel Tank....3293
Fuel Tank and Associated Parts....3293
Removal....3293
Installation....3294
Fuel Tube / Quick – Connect Fittings....3294
Precautions....3294
Cautions During Work....3294
Removal....3294
Reuse of Quick–Connector....3296
Assembling Advice....3296
Fuel Gauge Unit....3297
Fuel Gauge Unit and Associated Parts....3297
Removal....3297
Installation....3297
Fuel Filler Cap....3298
General Description....3298
Inspection....3298
Main Data and Specifications....3298
6D1 ENGINE ELECTRICAL....3299
Service Precaution....3299
Battery....3300
General Description....3300
Diagnosis....3300
Battery Charging....3301
Jump Starting....3301
Battery Removal....3302
Battery Installation....3302
Main Data and Specifications....3303
6D2 IGNITION SYSTEM....3305
Service Precaution....3305
General Description....3306
Diagnosis....3306
Ignition Coil....3307
Removal....3307
Inspection and Repair....3307
Installation....3307
Spark Plug....3308
Removal....3308
Inspection and Repair....3308
Installation....3308
Crankshaft Angle Sensor....3309
Removal....3309
Installation....3309
Main Data and Specifications....3310
6D3 STARTING AND CHARGING SYSTEM....3311
Service Precaution....3311
Starting System....3312
General Description....3312
Diagnosis....3314
Starter....3315
Removal....3315
Installation....3315
Disassembled View....3316
Disassembly....3317
Inspection and Repair....3319
Reassembly....3323
Main Data and Specifications....3325
Charging System....3328
General Description....3328
General On–Vehicle Inspection....3328
Generator....3329
Removal....3329
Inspection....3329
Installation....3329
Disassembled View....3330
Disassembly....3331
Inspection and Repair....3333
Reassembly....3334
Bench Test....3335
Main Data and Specifications....3336
6E ENGINE DRIVEABILITY AND EMISSIONS....3337
Specifications....3341
Tightening Specifications....3341
Vehicle Type Specifications....3341
Diagrams and Schematics....3342
PCM Wiring Diagram (1 of 11)....3342
PCM Wiring Diagram (2 of 11) For EC, THAILAND, SOUTH EAST ASIA, LATIN AMERICA, GULF, SAUDI, CHINA.....3343
PCM Wiring Diagram (3 of 11) For SOUTH AFRICA and EXP.....3344
PCM Wiring Diagram (4 of 11)....3345
PCM Wiring Diagram (5 of 11)....3346
PCM Wiring Diagram (6 of 11) For AUSTRALIA, THAILAND, SOUTH EAST ASIA, LATIN AMERICA, GULF, SAUDI, LATIN AMERICA.....3347
PCM Wiring Diagram (7 of 11) For EC.....3348
PCM Wiring Diagram (8 of 11) For EXPORT and SOUTH AFRICA.....3349
PCM Wiring Diagram (9 of 11) Except EXP and SOUTH AFRICA....3350
PCM Wiring Diagram (10 of 11) For EXPORT and SOUTH AFRICA....3351
PCM Wiring Diagram (11 of 11)....3352
PCM Pinouts....3353
PCM Pinout Table, 32-Way Red Connector – Row “A”....3353
PCM Pinout Table, 32-Way Red Connector – Row “B”....3355
PCM Pinout Table, 32-Way White Connector – Row “C” (For EC)....3356
PCM Pinout Table, 32-Way White Connector – Row “C” (For except EC)....3357
PCM Pinout Table, 32-Way White Connector ‐ Row “D” (For except EXPORT and SOUTH AFRICA)....3358
PCM Pinout Table, 32-Way White Connector ‐ Row “D” (For EXPORT and SOUTH AFRICA)....3359
PCM Pinout Table, 32-Way Blue Connector ‐ Row “E” (For except EXPORT and SOUTH AFRICA)....3360
PCM Pinout Table, 32-Way Blue Connector ‐ Row “E” (For EXPORT and SOUTH AFRICA)....3362
PCM Pinout Table, 32-Way Blue Connector ‐ Row “F”....3363
Component Locators....3364
Engine Component Locator (This illustration is based on RHD model.)....3364
Engine Component Locator Table....3365
Engine Component Locator Table....3367
Undercarriage Component Locator....3368
Undercarriage Component Locator Table (Automatic Transmission)....3368
Undercarriage Component Locator Table (Manual Transmission)....3369
Fuse and Relay Panel (Underhood Electrical Center)....3369
Sensors and Miscellaneous Component Locators....3370
Diagnosis....3373
Strategy-Based Diagnostics....3373
Strategy-Based Diagnostics....3373
DTC Stored....3373
No DTC....3373
No Matching Symptom....3373
Intermittents....3373
No Trouble Found....3373
Verifying Vehicle Repair....3373
General Service Information....3374
OBD Serviceablity Issues....3374
Maintenance Schedule....3374
Visual / Physical Engine Compartment Inspection....3374
Basic Knowledge of Tools Required....3374
Serial Data Communications....3374
Class II Serial Data Communications....3374
On-Board Diagnostic (OBD)....3375
On-Board Diagnostic Tests....3375
Comprehensive Component Monitor Diagnostic Operation....3375
Common OBD Terms....3376
The Diagnostic Executive....3376
DTC Types....3377
Verifying Vehicle Repair....3378
Reading Diagnostic Trouble Codes Using A Tech 2....3378
Tech 2....3379
Tech 2 Features....3379
Getting Started....3380
Operating Procedure (For Example)....3380
DTC Modes....3381
DTC Information Mode....3382
Injector Balance Test....3382
EGR Control Test....3383
Idle Air Control System Test....3384
Primary System-Based Diagnostic....3386
Primary System-Based Diagnostic....3386
Fuel Control Heated Oxygen Sensor....3386
HO2S Heater....3386
Fuel Trim System Monitor Diagnostic Operation....3386
Fuel Trim System Monitor Diagnostic Operation....3386
Fuel Trim Cell Diagnostic Weights....3386
On-Board Diagnostic (OBD) System Check....3387
A/C Clutch Control Circuit Diagnosis....3390
Electronic Ignition System Diagnosis....3396
Fuel Metering System Check....3396
Idle Air Control (IAC) Valve....3396
Fuel System Pressure Test....3396
Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure....3396
Knock Sensor Diagnosis....3401
Powertrain Control Module (PCM) Diagnosis....3401
Multiple PCM Information Sensor DTCS Set....3401
Exhaust Gas Recirculation (EGR) Diagnosis (For except EXPORT and SOUTH AFRICA)....3404
Engine Tech 2 Data Definitions and Ranges....3404
Typical Scan Data Values....3406
No Malfunction Indicator Lamp (MIL)....3410
Malfunction Indicator Lamp (MIL) “ON” Steady....3413
Engine Cranks But Will Not Run....3415
Fuel System Electrical Test....3421
Fuel System Diagnosis....3424
Idle Air Control (IAC) System Check....3429
Knock Sensor (KS) System Check (Engine Knock, Poor Performance, or Poor Economy)....3431
Exhaust Gas Recirculation (EGR) System Check....3433
Manifold Absolute Pressure (MAP) Output Check....3435
PCM Diagnostic Trouble Codes....3437
Diagnostic Trouble Code (DTC) P0101 MAF System Performance....3440
Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency....3443
Diagnostic Trouble Code (DTC) P0103 MAF Sensor Circuit High Frequency....3446
Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage....3448
Diagnostic Trouble Code (DTC) P0108 MAP Sensor Circuit High Voltage....3451
Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage....3454
Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage....3457
Diagnostic Trouble Code (DTC) P0117 ECT Sensor Circuit Low Voltage....3460
Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage....3463
Diagnostic Trouble Code (DTC) P0121 TP System Performance....3466
Diagnostic Trouble Code (DTC) P0122 TP Sensor Circuit Low Voltage....3469
Diagnostic Trouble Code (DTC) P0123 TP Sensor Circuit High Voltage....3472
Diagnostic Trouble Code (DTC) P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1....3475
Diagnostic Trouble Code (DTC) P0132 HO2S Circuit High Voltage Bank 1 Sensor 1....3478
Diagnostic Trouble Code (DTC) P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1....3481
Diagnostic Trouble Code (DTC) P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1....3484
Diagnostic Trouble Code (DTC) P0152 HO2S Circuit HIGH Voltage Bank 2 Sensor 1....3487
Diagnostic Trouble Code (DTC) P0171 Fuel Trim System Lean Bank 1....3490
Diagnostic Trouble Code (DTC) P0172 Fuel Trim System Rich Bank 1....3494
Diagnostic Trouble Code (DTC) P0174 Fuel Trim System Lean Bank 2....3498
Diagnostic Trouble Code (DTC) P0175 Fuel Trim System Rich Bank 2....3502
Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit....3506
Diagnostic Trouble Code (DTC) P0202 Injector 2 Control Circuit....3509
Diagnostic Trouble Code (DTC) P0203 Injector 3 Control Circuit....3512
Diagnostic Trouble Code (DTC) P0204 Injector 4 Control Circuit....3515
Diagnostic Trouble Code (DTC) P0205 Injector 5 Control Circuit....3518
Diagnostic Trouble Code (DTC) P0206 Injector 6 Control Circuit....3521
Diagnostic Trouble Code (DTC) P0325 KS Module Circuit....3524
Diagnostic Trouble Code (DTC) P0327 KS Sensor Circuit....3526
Diagnostic Trouble Code (DTC) P0336 58X Reference Signal Circuit....3529
Diagnostic Trouble Code (DTC) P0337 CKP Sensor Circuit Low Frequency....3531
Diagnostic Trouble Code (DTC) P0341 CMP Sensor Circuit Performance....3534
Diagnostic Trouble Code (DTC) P0342 CMP Sensor Circuit Low....3538
Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit....3542
Diagnostic Trouble Code (DTC) P0352 Ignition 2 Control Circuit....3545
Diagnostic Trouble Code (DTC) P0353 Ignition 3 Control Circuit....3548
Diagnostic Trouble Code (DTC) P0354 Ignition 4 Control Circuit....3551
Diagnostic Trouble Code (DTC) P0355 Ignition 5 Control Circuit....3554
Diagnostic Trouble Code (DTC) P0356 Ignition 6 Control Circuit....3557
Diagnostic Trouble Code (DTC) P0402 EGR Pintle Crank Error....3560
Diagnostic Trouble Code (DTC) P0404 EGR Open Stuck....3562
Diagnostic Trouble Code (DTC) P0405 EGR Low Voltage....3564
Diagnostic Trouble Code (DTC) P0406 EGR High Voltage....3567
Diagnostic Trouble Code (DTC) P0502 VSS Circuit Low Input....3570
Diagnostic Trouble Code (DTC) P0562 System Voltage Low....3573
Diagnostic Trouble Code (DTC) P0563 System Voltage High....3575
Diagnostic Trouble Code (DTC) P0601 PCM Memory....3576
Diagnostic Trouble Code (DTC) P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1....3577
Diagnostic Trouble Code (DTC) P1171 Fuel System Lean During Acceleration....3581
Diagnostic Trouble Code (DTC) P1380 ABS Rough Road ABS System Fault....3584
Diagnostic Trouble Code (DTC) P1404 EGR Closed Stuck....3585
Diagnostic Trouble Code (DTC) P1508 IAC System Low RPM....3587
Diagnostic Trouble Code (DTC) P1509 IAC System High RPM....3590
Diagnostic Trouble Code (DTC) P1618 Serial Peripheral Interface (SPI) PCM Interprocessor Communication Error....3593
Diagnostic Trouble Code (DTC) P1625 PCM Unexpected Reset....3594
Diagnostic Trouble Code (DTC) P1640 Driver-1-Input High Voltage....3595
Symptom Diagnosis....3598
Default Matrix Table....3624
Camshaft Position (CMP) Sensor....3627
Crankshaft Position (CKP) Sensor....3628
Engine Coolant Temperature (ECT) Sensor....3628
Heated Oxygen Sensor (HO2S)....3629
Intake Air Temperature (IAT) Sensor....3631
Knock Sensor (KS)....3632
Mass Air Flow (MAF) Sensor....3633
Manifold Absolute Pressure (MAP) Sensor....3633
Malfunction Indicator Lamp (MIL)....3634
Powertrain Control Module (PCM)....3634
EEPROM....3636
Power Steering Pressure (PSP) Switch....3636
Throttle Position (TP) Sensor....3637
Vehicle Speed Sensor (VSS)....3638
Air Cleaner/Air Filter....3639
Idle Air Control (IAC) Valve....3640
Common Chamber....3641
Accelerator Cable Assembly....3641
Accelerator Pedal Replacement....3644
Fuel Filter Cap....3646
Fuel Filter....3646
Fuel Gauge Unit....3649
Fuel Injectors....3650
Fuel Pressure Regulator....3651
Fuel Metering System....3653
Fuel Pump Assembly....3654
Fuel Pump Relay....3655
Fuel Rail Assembly....3655
Fuel Tank....3657
Throttle Body (TB)....3659
Electronic Ignition System....3660
Catalytic Converter....3661
Air Conditioning Relay....3661
EVAP Canister Hoses....3662
EVAP Canister....3662
EVAP Canister Purge Solenoid....3663
Fuel Tank Vent Valve....3664
Linear Exhaust Gas Recirculation (EGR) Valve....3664
Positive Crankcase Ventilation (PCV) Valve....3665
Wiring and Connectors....3666
PCM Connectors and Terminals....3666
Wire Harness Repair: Twisted Shielded Cable....3666
Twisted Leads....3667
Weather-Pack Connector....3668
Com-Pack III....3669
Metri-Pack....3669
General Description....3671
General Description (PCM and Sensors)....3671
58X Reference PCM Input....3671
A/C Request Signal....3671
Crankshaft Position (CKP) Sensor....3671
Camshaft Position (CMP) Sensor and Signal....3671
Engine Coolant Temperature (ECT) Sensor....3671
Electrically Erasable Programmable Read Only Memory (EEPROM)....3672
Fuel Control Heated Oxygen Sensors....3672
Intake Air Temperature (IAT) Sensor....3672
Knock Sensor....3673
Linear Exhaust Gas Recirculation (EGR) Control....3673
Mass Air Flow (MAF) Sensor....3673
Manifold Absolute Pressure (MAP) Sensor....3674
Powertrain Control Module (PCM)....3674
PCM Function....3674
PCM Components....3675
PCM Voltage Description....3675
PCM Input/Outputs....3675
PCM Service Precautions....3675
Reprogramming The PCM....3675
Throttle Position (TP) Sensor....3675
Transmission Fluid Temperature (TFT) Sensor....3676
Transmission Range Switch....3676
Vehicle Speed Sensor (VSS)....3676
Use of Circuit Testing Tools....3676
Aftermarket Electrical and Vacuum Equipment....3676
Electrostatic Discharge Damage....3677
Upshift Lamp....3677
General Description (Air Induction)....3677
Air Induction System....3677
General Description (Fuel Metering)....3677
Acceleration Mode....3677
Accelerator Controls....3677
Battery Voltage Correction Mode....3677
CMP Signal....3677
Clear Flood Mode....3678
Deceleration Mode....3678
Engine Speed/Vehicle Speed/Fuel Disable Mode....3678
Fuel Cutoff Mode....3678
Fuel Injector....3678
Fuel Metering System Components....3678
Fuel Metering System Purpose....3678
Fuel Pressure Regulator....3679
Fuel Pump Electrical Circuit....3679
Fuel Rail....3679
Idle Air Control (IAC) Valve....3679
Run Mode....3680
Starting Mode....3680
Throttle Body Unit....3680
General Description (Electronic Ignition System)....3680
Camshaft Position (CMP) Sensor....3680
Crankshaft Position (CKP) Sensor....3681
Electronic Ignition....3681
Ignition Coils....3681
Ignition Control....3681
Ignition Control PCM Output....3683
Knock Sensor (KS) PCM Input....3683
Powertrain Control Module (PCM)....3683
Spark Plug....3683
A/C Clutch Diagnosis....3685
A/C Clutch Circuit Operation....3685
A/C Clutch Circuit Purpose....3685
A/C Request Signal....3685
General Description (Exhaust Gas Recirculation (EGR) System)....3685
EGR Purpose....3685
Linear EGR Valve....3685
Linear EGR Control....3685
Linear EGR Valve Operation and Results of Incorrect Operation....3685
EGR Pintle Position Sensor....3686
General Description (Positive Crankcase Ventilation (PCV) System)....3686
Crankcase Ventilation System Purpose....3686
Crankcase Ventilation System Operation....3686
6F ENGINE EXHAUST....3691
Service Precaution....3691
General Description....3692
Front Exhaust Pipe....3694
Front Exhaust Pipe and Associated Parts....3694
Removal....3694
Installation....3694
Three Way Catalytic Converter....3695
Removal....3695
Installation....3695
Exhaust Silencer....3696
Exhaust Silencer and Associated Parts....3696
Removal....3696
Installation....3696
Rear Exhaust pipe....3697
Rear Exhaust pipe and Associated Parts....3697
Removal....3697
Installation....3697
Main Data and Specifications....3698
6G ENGINE LUBRICATION....3699
Service Precaution....3699
General Description....3700
Oil Pump....3701
Oil Pump and Associated Parts....3701
Oil Pump and Associated Parts....3701
Inspection and Repair....3702
Reassembly....3703
Oil Pan and Crankcase....3705
Removal....3705
Installation....3705
Oil Pump....3708
Removal....3708
Installation....3708
Oil Pump Oil Seal....3710
Removal....3710
Installation....3710
Oil Filter....3711
Removal....3711
Installation....3711
Main Data and Specification....3712
Special Tool....3713
6H ENGINE SPEED CONTROL SYSTEM....3714
Service Precaution....3714
Accelerator Pedal Control Cable....3715
Removal....3715
Inspection....3715
Installation....3715
Adjustment....3715
Accelerator Pedal....3716
Accelerator Pedal and Associated Parts....3716
Removal....3716
Installation....3716
Adjustment....3716
6J INDUCTION....3718
Service Precaution....3718
Air Cleaner Element....3719
Removal....3719
Inspection....3719
Installation....3719
Sec.6 ENGINE(4JG2)....3720
00 SERVICE INFORMATION....3720
TROUBLESHOOTING....3721
MAIN DATA AND SPECIFICATIONS....3739
SERVICE STANDARD....3742
SERVICING....3746
FIXING TORQUE....3757
SPECIAL TOOLS....3766
6A ENGINE MECHANICAL....3770
CYLINDER HEAD....3771
VALVE SPRING, VALVE STEM OIL SEAL, VALVE, VALVE GUIDE, PUSH ROD....3776
CAMSHAFT, TAPPET....3783
ROCKER ARM ASSEMBLY....3788
OIL PUMP....3790
CRANKSHAFT....3794
PISTON AND CONNECTING ROD....3803
CYLINDER BLOCK....3811
6A2 4JG2-NA/4JG2-TURBO ENGINE....3822
GENERAL DESCRIPTION....3822
ENGINE MOUNT (RH)....3824
ENGINE MOUNT (LH)....3825
INTERCOOLER (4JG2-T only)....3826
CYLINDER HEAD COVER....3827
INLET MANIFOLD....3829
EXHAUST MANIFOLD....3831
TURBOCHARGER (4JG2-T only)....3832
TIMING GEAR....3836
VALVE STEM OIL SEAL & VALVE SPRING....3842
ROCKER ARM SHAFT ASSEMBLY....3845
CYLINDER HEAD....3847
CRANKCASE....3852
OIL COOLER....3855
OIL PUMP ASSEMBLY....3857
PISTON, PISTON RING AND CONNECTING ROD....3858
CRANKSHAFT AND MAIN BEARING....3860
FRONT OIL SEAL....3866
REAR OIL SEAL....3867
ENGINE ASSEMBLY....3869
6B ENGINE COOLING....3874
GENERAL DESCRIPTION....3874
ON-VEHICLE SERVICE....3878
WATER PUMP....3878
THERMOSTAT....3880
RADIATOR....3882
6C FUEL SYSTEM....3886
GENERAL DESCRIPTION....3886
ON-VEHICLE SERVICE....3892
FUEL FILTER ASSEMBLY....3892
FUEL FILTER CARTRIGE....3893
INJECTION NOZZLE....3894
INJECTION PUMP ASSEMBLY....3899
FUEL TANK....3903
FUEL GAUGE UNIT....3904
FUEL FILLER CAP....3905
ACCELERATOR CONTROL....3906
ACCELERATOR CONTROL CABLE....3906
ACCELERATOR PEDAL....3908
AIR CLEANER....3909
6D ENGINE ELECTRICAL....3910
6D1 BATTERY....3910
GENERAL DESCRIPTION....3910
DIAGNOSIS....3910
ON-VEHICLE SERVICE....3912
BATTERY CHARGING....3912
JUMP STARTING....3912
REMOVAL AND INSTALLATION OF THE BATTERY....3913
6D2 STARTING SYSTEM....3914
GENERAL DESCRIPTION....3914
ON-VEHICLE SERVICE....3916
UNIT REPAIR....3918
6D3 CHARGING SYSTEM....3926
GENERAL DESCRIPTION....3926
DIAGNOSIS....3929
UNIT REPAIR....3930
6D6 QOSIII PREHEATING SYSTEM....3938
GENERAL DESCRIPTION....3938
SYSTEM DIAGRAM....3939
6F ENGINE EXHAUST....3944
GENERAL DESCRIPTION....3945
HANGERS....3945
GASKET....3945
ON-VEHICLE SERVICE....3946
FRONT EXHAUST PIPE....3946
CENTER EXHAUST PIPE....3948
EXHAUST SILENCER....3950
REAR EXHAUST PIPE....3952
Sec.6 ENGINE(4JX1)....3953
6A ENGINE MECHANICAL....3953
6B ENGINE COOLING....4053
6C ENGINE FUEL....4065
6D ENGINE ELECTRICAL....4087
6E ENGINE DRIVEABILITY AND EMISSIONS....4113
6F ENGINE EXHAUST....4343
6G ENGINE LUBRICATION....4351
6H ENGINE SPEED CONTROL....4357
6J INDUCTION....4361
Sec.7 TRANSMISSION....4374
7A AUTOMATIC TRANSMISSION (4L30‐E)....4374
Service Precaution....4376
Construction....4376
Range Reference Chart....4377
Normal Operation Of 1998 4L30‐E Transmission....4378
Diagnosis....4378
Driver Information....4378
General Diagnosis Procedure....4381
Preliminary Inspection Chart....4382
Checking Transmission Fluid Level and Condition....4383
Test Driving....4384
Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart....4385
Mechanical / Hydraulic Diagnosis Symptoms Index....4386
Stall Test....4396
Line Pressure Test....4396
Shift Speed Chart....4397
Lockup Speed Chart....4399
Changing Transmission Fluid....4400
Selector Lever....4400
Inspection....4400
Removal....4401
Installation....4401
Mode Switch....4402
Removal....4402
Installation....4402
Transmission (With Transfer Case)....4404
Transmission And Associated Parts....4404
Removal....4404
Installation....4406
Solenoid (Main Case Valve Body)....4409
Removal....4409
Installation....4409
Solenoid (Adapter Case Valve Body)....4410
Removal....4410
Installation....4410
Valve Body Assembly (Main Case)....4411
Removal....4411
Installation....4411
Valve Body Assembly (Adapter Case)....4413
Removal....4413
Installation....4413
Powertrain Control Module (PCM)....4413
Removal....4413
Installation....4413
Speed Sensor (Extension Housing)....4414
Removal....4414
Installation....4414
Transmission Oil Temperature Sensor (Adapter Case)....4414
Removal....4414
Installation....4415
Front Oil Seal (Converter Housing)....4415
Removal....4415
Installation....4415
Rear Oil Seal (Extension Housing)....4416
Removal....4416
Installation....4416
Transmission (4L30–E)....4416
Disassembly....4416
Reassembly....4420
Converter Housing And Oil Pump Assembly....4430
Disassembled View....4430
Disassembly....4430
Inspection And Repair....4430
Reassembly....4430
Oil Pump....4431
Disassembled View....4431
Disassembly....4431
Inspection And Repair....4431
Reassembly....4431
Main Case Valve Body....4432
Disassembled View....4432
Disassembly....4432
Inspection And Repair....4433
Reassembly....4433
Adapter Case Valve Body....4434
Disassembled View....4434
Disassembly....4434
Inspection And Repair....4434
Reassembly....4434
Third Clutch And Sprag Unit....4436
Disassembled View....4436
Disassembly....4436
Inspection And Repair....4437
Reassembly....4437
Third Clutch....4438
Disassembled View....4438
Disassemble....4438
Inspection And Repair....4438
Reassembly....4438
Sprag Unit....4440
Disassembled View....4440
Disassembly....4440
Inspection And Repair....4440
Reassembly....4440
Second Clutch....4441
Disassembled View....4441
Disassembly....4441
Inspection And Repair....4442
Reassembly....4442
3–4 Accumulator Piston....4443
Disassembled View....4443
Disassembly....4443
Inspection And Repair....4443
Reassembly....4444
Reverse Clutch Piston And Center Support....4445
Disassembled View....4445
Disassembly....4445
Inspection And Repair....4446
Reassembly....4446
Overrun Clutch And Turbine Shaft....4447
Disassembled View....4447
Disassembly....4447
Inspection And Repair....4448
Reassembly....4448
Main Data And Specification....4450
Special Tools....4454
4L30–E Parts List....4457
7A1 TRANSMISSION CONTROL SYSTEM (4L30‐E)....4465
Service Precaution....4466
General Description....4466
Shift Control....4470
Band Apply Control....4470
Torque Converter Clutch Control....4470
Line Pressure Control....4470
On–Board Diagnostic System....4470
Fail Safe Mechanism....4470
Torque Management Control....4470
ATF Warning Control....4470
ABS Control (If equipped)....4470
Winter Drive Mode....4473
Backup Mode....4473
Functions of Input / Output Components....4474
Diagnosis....4475
Check Trans Indicator....4475
Diagnostic Check....4475
“Check Trans” Check....4476
Tech2 OBD II Connection....4477
OBD II Diagnostic Management System....4482
16 – Terminal Data Link Connector (DLC)....4483
Malfunction Indicator Lamp (MIL)....4484
Types Of Diagnostic Trouble Codes (DTCs)....4484
Clear DTC....4484
DTC Check....4485
PCM Precaution....4485
Information On PCM....4485
Intermittent Conditions....4485
Transmission And PCM Identification....4486
Diagnostic Trouble Code (DTC) Identification....4488
DTC P0218 Transmission Fluid Over Temperature....4489
Conditions For Setting The DTC....4489
Action Taken When The DTC Sets....4489
Conditions For Clearing The DTC....4489
Diagnostic Aids....4489
Test Description....4489
DTC P0560 System Voltage Malfunction....4491
DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position....4494
DTC P0706 Transmission Range Switch (Mode Switch) Performance....4497
DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input....4500
DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input....4503
DTC P0719 TCC Brake Switch Circuit High (Stuck On)....4506
DTC P0722 Transmission Output Speed Sensor (OSS) Low Input....4509
DTC P0723 Transmission Output Speed Sensor (OSS) Intermittent....4512
DTC P0730 Transmission Incorrect Gear Ratio....4515
DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical....4518
DTC P0753 Shift Solenoid A Electrical....4520
DTC P0758 Shift Solenoid B Electrical....4523
DTC P1790 ROM Transmission Side Bad Check Sum....4527
DTC P1792 EEPROM Transmission Side Bad Check Sum....4528
DTC P1835 Kickdown Switch Always On....4529
DTC P1850 Brake Band Apply Solenoid Malfunction....4531
DTC P1860 TCC Solenoid Electrical....4535
7B MANUAL TRANSMISSION (AR-5)....4538
Service Precaution....4538
General Description....4539
Diagnosis....4541
Manual Transmission Assembly....4542
Transmission and Associated Parts....4542
Removal....4543
Installation....4548
Rear Oil Seal (Transfer Adapter)....4554
Removal....4554
Installation....4554
Transmission (AR-5)....4555
Disassembled View....4555
Disassembly....4558
Inspection....4576
Reassembly....4578
Main Data and Specifications....4605
General Specifications....4605
Torque Specifications....4606
Special Tools....4609
7B MANUAL TRANSMISSION (MUA)....4611
4X2 MODEL TRANSMISSION....4612
Main Data and Specifications....4612
General Description....4613
Torque Specifications....4614
Recommended Liquid Gasket....4616
Removal and Installation....4617
Disassembly....4626
Inspection and Repair....4636
Reassembly....4641
4X4 MODEL TRANSMISSION....4656
Main Data and Specifications....4656
General Description....4657
Torque Specifications....4658
Recommended Liquid Gasket....4660
Removal and Installation....4661
Disassembly....4671
Inspection and Repair....4691
Reassembly....4697
Troubleshooting....4722
7C CLUTCH....4730
Service Precaution....4730
Diagnosis....4736
Clutch Assembly....4737
Clutch Assembly and Associated Parts....4737
Removal....4737
Inspection and Repair....4738
Installation....4743
Clutch Control....4745
Clutch Control Parts....4745
Removal....4746
Inspection and Repair....4746
Installation....4747
Adjustment....4747
Master Cylinder....4750
Disassembled View....4750
Disassembly....4751
Inspection and Repair....4751
Reassembly....4751
Slave Cylinder....4752
Disassembled View....4752
Disassembly....4752
Inspection and Repair....4752
Reassembly....4753
Damper Cylinder....4754
Disassembled View....4754
Disassembly....4754
Inspection and Repair....4754
Reassembly....4754
Main Data and Specifications....4755
General Specifications....4755
Torque Specifications....4755
Special Tools....4758
Sec.8 BODY AND ACCESSORIES....4759
8A LIGHTING SYSTEM....4759
Service Precaution....4760
Headlight Bulb....4761
Removal....4761
Installation....4761
Headlight....4762
Headlight and Associated Parts....4762
Removal....4762
Installation....4762
Headlight Adjustment....4762
Fog Light Bulb....4763
Removal....4763
Installation....4763
Fog Light Assembly....4764
Removal....4764
Installation....4764
Fog Light Adjustment....4764
Clarence Light Bulb....4764
Removal....4764
Installation....4764
Rear Fog Light Bulb (RHD)....4765
Removal....4765
Installation....4765
Taillight Bulb (Body)....4765
Removal....4765
Installation....4765
Taillight Bulb (Bumper)....4766
Removal....4766
Installation....4766
License Plate Light Bulb (Body)....4766
Removal....4766
Installation....4766
License Plate Light Bulb (Bumper)....4767
Removal....4767
Installation....4767
Stoplight Bulb....4767
Removal and Installation....4767
High Mount Stoplight....4768
Removal....4768
Installation....4768
Front Turn Signal Light Bulb....4768
Removal....4768
Installation....4768
Side Turn Signal Light Bulb....4769
Removal....4769
Installation....4769
Rear Turn Signal Light Bulb....4769
Removal....4769
Installation....4769
Backup Light Bulb....4770
Removal....4770
Installation....4770
Dome Light Bulb....4770
Removal....4770
Installation....4770
Luggage Room Light Bulb....4771
Removal....4771
Installation....4771
Courtesy Light Bulb....4771
Removal....4771
Installation....4771
Map Light Switch/Bulb....4772
Removal....4772
Installation....4772
Cigarette Lighter Illumination Bulb....4772
Removal....4772
Installation....4772
Ashtray Illumination Bulb....4773
Removal....4773
Installation....4773
Glove Box Illumination Bulb....4773
Removal....4773
Installation....4773
Vanity Mirror Illumination Bulb....4774
Removal....4774
Installation....4774
Starter Switch....4775
Removal....4775
Installation....4775
Lighting Switch (Combination Switch)....4776
Removal....4776
Installation....4776
Fog Light Switch....4777
Removal....4777
Installation....4777
Stoplight Switch (W/O Cruise Control)....4778
Removal....4778
Installation....4778
Brake Switch (W/Cruise Control)....4779
Removal....4779
Installation....4779
Turn Signal Switch (Combination Switch)....4779
Removal and Installation....4779
Hazard Warning Switch....4780
Removal....4780
Installation....4780
Tailgate Switch....4781
Removal....4781
Installation....4781
Door Switch....4781
Removal....4781
Installation....4781
Rear Defogger Switch....4782
Removal....4782
Installation....4782
Seat Heater Switch....4783
Removal....4783
Installation....4783
Key Remind Switch (Starter Switch)....4783
Removal and Installation....4783
Illumination Controller....4784
Removal....4784
Installation....4784
Power/Winter Switch....4785
Removal....4785
Installation....4785
Main Data and Specifications....4786
8B WIPER / WASHER SYSTEM....4789
Service Precaution....4790
Windshield Wiper/Washer System....4790
General Description....4790
Windshield Wiper And Washer Switch....4790
Removal and Installation....4790
Windshield Wiper Motor....4790
Removal....4790
Installation....4790
Windshield Washer Motor....4791
Removal....4791
Installation....4791
Windshield Wiper Linkage....4792
Windshield Wiper Linkage and Associated Parts....4792
Removal....4792
Installation....4792
Windshield Wiper Arm/Blade....4793
Removal....4793
Installation....4793
Windshield Wiper Blade Rubber....4794
Removal....4794
Installation....4794
Rear Wiper/Washer System....4795
General Description....4795
Rear Wiper and Washer Switch....4795
Removal....4795
Installation....4795
Rear Wiper Motor....4796
Removal....4796
Installation....4796
Alarm & Relay Control Unit....4797
Removal....4797
Installation....4797
Rear Washer Motor....4797
Removal....4797
Installation....4797
Rear Wiper Arm/Blade....4798
Removal....4798
Installation....4798
Rear Washer Nozzle....4798
Removal....4798
Installation....4798
Rear Washer Nozzle Angle Adjustment....4798
Rear Wiper Blade Rubber....4799
Removal and Installation....4799
Headlight Wiper/Washer....4799
General Description....4799
Headlight Wiper and Washer Switch....4800
Removal....4800
Installation....4800
Headlight Wiper Arm & Blade....4801
Removal....4801
Installation....4801
Headlight Wiper Motor....4801
Removal....4801
Installation....4801
Headlight Washer Motor....4802
Removal and Installation....4802
Main Data and Specifications....4802
8C ENTERTAINMENT....4803
Service Precaution....4803
Cigarette Lighter....4804
General Description....4804
Removal....4804
Installation....4804
Digital Clock....4805
Removal....4805
Installation....4805
Rod Type Antenna....4806
Removal....4806
Installation....4806
Auto Antenna....4807
General Description....4807
Removal....4807
Installation....4807
Antenna Rod....4808
Removal....4808
Installation....4808
Radio....4809
Removal....4809
Installation....4809
Front Speaker....4810
Removal....4810
Installation....4810
Rear Speaker....4811
Removal....4811
Installation....4811
8D WIRING SYSTEM....4813
Service Precaution....4815
General Description....4816
Notes for Working on Electrical Items....4816
Symbols and Abbreviations....4822
Parts for Electrical Circuit....4824
Reading the Circuit Diagram....4833
Main Data and Specifications....4836
Fuse, Fusible Link and Circuit Breaker Location....4836
Relay Location-1....4839
Diode Location....4842
Grounding Point....4845
Cable Harness Routing....4857
Fuse Block Circuit....4865
Circuit Diagram....4866
Start and Charging....4879
General Description....4879
Circuit Diagram....4880
Parts Location....4882
Powertrain Control Module (PCM)....4892
General Description....4892
Circuit Diagram....4893
Parts Location....4905
QOS-III (4JG2)....4923
General Description....4923
Circuit Diagram....4924
Parts Location....4926
QOS and EGR System (4JG2)....4930
General Description....4930
Circuit Diagram....4931
Parts Location....4934
Headlight and Fog Light....4939
General Description....4939
Circuit Diagram....4940
Parts Location....4942
Diagnosis....4946
Rear Fog Light....4962
Circuit Diagram....4963
Parts Location....4964
Headlight Leveling....4965
General Description....4965
Circuit Diagram....4966
Parts Location....4967
Diagnosis....4968
Clearance Light, Taillight and License Plate Light....4971
General Description....4971
Circuit Diagram....4972
Parts Location....4975
Diagnosis....4980
Interior Illumination Light....4992
General Description....4992
Circuit Diagram....4993
Parts Location....4997
Diagnosis....5004
Turn Signal Light and Hazard Warning Light....5005
General Description....5005
Circuit Diagram....5006
Parts Location....5009
Diagnosis....5014
Stoplight....5020
General Description....5020
Circuit Diagram....5021
Parts Location....5024
DIAGNOSIS....5028
Backup Light....5032
General Description....5032
Circuit Diagram....5033
Parts Location....5035
Diagnosis....5039
Horn....5042
General Description....5042
Circuit Diagram....5043
Parts Location....5044
Diagnosis....5047
Dome Light, Luggage Room Light, Courtesy Light and Map Light....5049
General Description....5049
Circuit Diagram....5050
Parts Location....5052
Power Door Lock....5056
General Description....5056
Circuit Diagram....5057
Parts Location....5062
Diagnosis....5068
Power Window....5073
General Description....5073
Circuit Diagram....5074
Parts Location....5075
Diagnosis....5078
Cruise Control....5084
General Description....5084
Circuit Diagram....5085
Parts Location....5087
Diagnosis....5091
Anti-lock Brake System (ABS)....5096
General Description....5096
Circuit Diagram....5097
Parts Location....5103
A/T Shift Lock....5110
General Description....5110
Circuit Diagram....5111
Parts Location....5112
Windshield Wiper/Washer....5115
General Description....5115
Circuit Diagram....5116
Parts Location....5117
Diagnosis....5120
Rear Wiper/Washer....5128
General Description....5128
Circuit Diagram....5129
Parts Location....5131
Diagnosis....5135
Headlight Wiper/Washer....5141
General Description....5141
Circuit Diagram....5142
Parts Location....5144
Diagnosis....5148
Rear Defogger....5154
General Description....5154
Circuit Diagram....5155
Parts Location....5156
Diagnosis....5159
Audio....5162
General Description....5162
Circuit Diagram....5163
Parts Location....5167
Cigarette Lighter and Digital Clock....5171
General Description....5171
Circuit Diagram....5172
Parts Location....5173
Power Door Mirror....5176
General Description....5176
Circuit Diagram....5177
Parts Location....5180
Diagnosis....5185
Anti-Theft System with Keyless Entry....5192
Circuit Diagram....5193
Parts Location....5204
Diagnosis....5211
Meter and Warning/Indicator Light....5222
General Description....5222
Circuit Diagram....5223
Parts Location....5241
Diagnosis....5257
A/T Shift Indicator....5276
General Description....5276
Circuit Diagram....5277
Parts Location....5279
Heater and Air Conditioning....5283
General Description....5283
Circuit Diagram....5284
Parts Location....5286
Sun Roof....5296
General Description....5296
Circuit Diagram....5297
Parts Location....5298
Diagnosis....5301
Seat Heater....5305
General Description....5305
Circuit Diagram....5306
Parts Location....5307
Diagnosis....5310
Power Seat....5312
General Description....5312
Circuit Diagram....5313
Parts Location....5315
Diagnosis....5319
Shift On The Fly System....5325
Circuit Diagram....5326
Parts Location....5328
Torque on Demand (T.O.D.)....5350
Circuit Diagram....5351
Parts Location....5354
Supplemental Restraint System (SRS) – Air Bag....5355
General Description....5355
Circuit Diagram....5356
Parts Location....5360
Connector List....5362
8E METER AND GAUGE....5397
Service Precaution....5397
General Description....5397
Meter Assembly....5398
General Description....5398
Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination Lights....5398
Table for Meter/Gauge Connector Terminal Connections....5404
Removal....5410
Installation....5410
Warning Light Bulb, Indicator Light Bulb, Illumination Light Bulb, A/T Indicator Light Bulb....5410
Removal....5410
Installation....5410
Vehicle Speed Sensor....5411
Removal....5411
Installation....5411
Fuel Tank Unit....5411
Removal....5411
Installation....5411
Multi Meter....5412
Removal....5412
Installation....5412
Ambient Sensor....5412
Removal....5412
Installation....5412
Main Data and Specifications....5413
8F BODY STRUCTURE....5415
Service Precaution....5417
Frame....5417
General Description....5417
Frame Dimensions (L W B)....5418
Frame Dimensions (S W B)....5419
General Description....5420
Front Bumper....5420
Parts Location....5420
Removal....5421
Installation....5421
Front Bumper Slider Bracket....5421
Removal....5421
Installation....5421
Rear Bumper....5422
Parts Location....5422
Removal....5422
Installation....5423
Parts Location (W/Rear Combination Light and License Light)....5424
Removal....5424
Installation....5425
Parts Location (W/Rear Combination Light)....5426
Removal....5426
Installation....5427
Rear Bumper Slider....5428
Removal....5428
Installation....5428
General Description....5429
Cowl Cover....5429
Parts Location....5429
Removal....5429
Installation....5430
Engine Hood....5430
Removal....5430
Installation....5430
Air Bulge....5431
Parts Location....5431
Removal....5431
Installation....5431
Engine Hood Hinge....5432
Parts Location....5432
Removal....5432
Installation....5432
Engine Hood Lock....5433
Parts Location....5433
Removal....5433
Installation....5434
Radiator Grille And Front End Lower Panel....5434
Parts Location....5434
Removal....5434
Installation....5435
Front Fender Panel....5436
Parts Location....5436
Removal....5436
Installation....5437
Body Mounting....5438
Parts Location....5438
Removal (No.1 – No. 2)....5438
Removal (No. 3 — No. 6)....5439
Installation....5440
General Description....5441
Body Dimension....5442
Instrument Panel Assembly....5462
Parts Location....5462
Removal....5463
Installation....5467
Cross Beam Assembly....5468
Parts Location....5468
Removal....5468
Installation....5469
Front Door Assembly....5470
Parts Location....5470
Removal....5470
Installation....5470
Rear Door Assembly....5471
Parts Location....5471
Removal....5471
Installation....5472
Door Strikers....5472
Adjustment....5472
Door Check Arm Assembly (Front & Rear)....5473
Parts Location....5473
Removal....5473
Installation....5474
Front Window Regulator, Glass And Glass Run....5474
Parts Location....5474
Removal....5474
Installation....5476
Rear Window Regulator And Glass....5477
Parts Location....5477
Removal....5477
Installation....5478
Rear Door Fixed Glass And Glass Run....5479
Parts Location....5479
Removal....5479
Installation....5480
Front Door Sash Moulding....5481
Parts Location....5481
Removal....5481
Installation....5481
Rear Door Moulding....5482
Parts Location....5482
Removal....5482
Installation....5482
Front Door Waist Seal....5483
Parts Location....5483
Removal....5483
Installation....5483
Rear Door Waist Seal....5484
Parts Location....5484
Removal and Installation....5484
Front Door Weatherstrip....5485
Parts Location....5485
Removal....5485
Installation....5486
Rear Door Weatherstrip....5487
Parts Location....5487
Removal and Installation....5487
Front Door Seal Finisher....5488
Parts Location....5488
Removal....5488
Installation....5488
Rear Door Seal Finisher....5489
Parts Location....5489
Removal....5489
Installation....5489
Tailgate Assembly (LH)....5490
Parts Location....5490
Removal....5490
Installation....5491
Tailgate Assembly (RH)....5492
Parts Location....5492
Removal....5492
Installation....5493
Tailgate Strikers....5494
Adjustment....5494
Tailgate Stopper Assembly....5494
Parts Location....5494
Removal....5494
Installation....5494
Tailgate Dove-Tail....5495
Parts Location....5495
Removal....5495
Installation....5495
Tailgate Dove-Tail Striker....5496
Adjustment....5496
Tailgate Frame Cover (LH)....5497
Parts Location....5497
Removal....5497
Installation....5497
Tailgate Frame Cover (RH)....5498
Removal....5498
Installation....5498
Tailgate Sash Trim Cover....5499
Parts Location....5499
Removal....5499
Installation....5499
Tailgate Outer Weatherstrip....5500
Parts Location....5500
Removal....5500
Installation....5500
Tailgate Center Weatherstrip....5501
Parts Location....5501
Removal....5501
Installation....5501
Tailgate Main Weatherstrip....5502
Parts Location....5502
Removal....5502
Installation....5502
Spare Tire Carrier....5503
Parts Location....5503
Removal....5503
Installation....5503
Headlining....5504
Parts Location....5504
Removal....5504
Installation....5505
Rear Air Deflector....5506
Parts Location....5506
Removal....5506
Installation....5506
Roof Moulding....5508
Parts Location....5508
Removal....5508
Installation....5509
Windshield....5510
Parts Location....5510
Removal....5510
Installation....5511
Rear Quarter Side Glass....5515
Parts Location....5515
Removal....5515
Installation....5516
Tailgate Glass....5518
Parts Location....5518
Removal....5518
Installation....5519
Main Data and Specifications....5520
Special Tools....5531
8G SEATS....5532
Service Precaution....5532
Front Seat Assembly....5533
Front Seat Assembly and Associated Parts....5533
Removal....5533
Installation....5534
Disassembled View (Long Wheel Base)....5534
Disassembly....5535
Reassembly....5536
Disassembled View (Short Wheel Base)....5537
Disassembly....5537
Reassembly....5539
Power Seat Assembly....5540
General Description....5540
Disassembled View....5540
Disassembly....5541
Reassembly....5543
Power Seat Switch....5543
Removal....5543
Installation....5543
Front Tilt Motor / Rear Tilt Motor / Slide Motor / Recliner Motor....5544
Parts Location....5544
Removal and Installation....5544
Seat Heater System....5545
General Description....5545
Seat Heater Switch Removal and Installation....5545
Heat Unit Parts Location....5545
Heat Unit Removal and Installation....5545
Rear Seat Assembly....5546
Rear Seat Assembly and Associated Parts....5546
Removal....5546
Installation....5546
Disassembled View (Split Type)....5547
Disassembly (Split Type)....5548
Reassembly (Split Type)....5549
Disassembled View (Short Wheel Base)....5550
Disassembly....5550
Reassembly....5551
Disassembled View (Bench Type)....5552
Disassembly (Bench Type)....5553
Reassembly (Bench Type)....5554
Third Seat Assembly....5554
Parts Location....5554
Removal....5554
Installation....5555
Disassembled View....5555
Disassembly....5556
Reassembly....5556
Rear Seat Foot Rest....5556
Rear Seat Foot Rest and Associated Parts....5556
Removal....5557
Installation....5557
Main Data and Specifications....5557
8H SECURITY AND LOCKS....5559
Service Precaution....5560
Front Door Lock Assembly....5560
Front Door Lock Assembly and Associated Parts....5560
Removal....5560
Installation....5561
Front Outside Handle and Door Lock Cylinder....5562
Front Outside Handle, Door Lock Cylinder and Associated Parts....5562
Removal....5562
Installation....5563
Rear Door Lock Assembly....5565
Rear Door Lock Assembly and Associated Parts....5565
Removal....5565
Installation....5566
Rear Outside Handle....5567
Rear Outside Handle and Associated Parts....5567
Removal....5567
Installation....5568
Rear Door Inside Lock Knob Link....5568
Removal....5568
Installation....5568
Door Inside Lock Knob....5569
Removal....5569
Installation....5569
Door Inside Handle....5569
Removal and Installation....5569
Tailgate Lock Assembly (LH)....5570
Tailgate Lock Assembly (LH) and Associated Parts....5570
Removal....5570
Installation....5571
Tailgate Lock Assembly (RH)....5572
Tailgate Lock Assembly (RH) and Associated Parts....5572
Removal....5572
Installation....5573
Tailgate Inside Lock Knob....5573
Removal....5573
Installation....5573
Tailgate Inside Handle....5574
Parts Location....5574
Removal and Installation....5574
Tailgate Outside Handle and/or Tailgate Lock Cylinder....5575
Tailgate Outside Handle and/or Tailgate Lock Cylinder and Associated Parts....5575
Removal....5575
Installation....5576
Key....5577
Key Coding....5577
Key Styles....5577
Power Door Lock System....5578
General Description....5578
Front Door Lock Actuator Removal....5578
Front Door Lock Actuator Installation....5578
Rear Door Lock Actuator Removal....5578
Rear Door Lock Actuator Installation....5579
Tailgate Lock Actuator Removal....5579
Tailgate Lock Actuator Installation....5579
Anti-theft System....5580
General Description....5580
Anti-theft & Keyless Entry Control Unit Removal....5580
Anti-theft & Keyless Entry Control Unit Installation....5580
Anti-theft Indicator Removal....5580
Anti-theft Indicator Installation....5581
Anti-theft Horn Removal....5581
Anti-Theft Horn Installation....5581
Engine Hood Switch Removal....5581
Engine Hood Switch Installation....5581
Keyless Entry System....5582
ID Code Registration....5582
Answer Back (Anti‐theft Horn Operation) Change Mode....5584
Anti‐theft & Keyless Entry Control Unit/Transmitter Replacement....5585
Main Data and Specifications....5586
8I SUN ROOF/CONVERTIBLE TOP....5587
Service Precaution....5587
Sun Roof Glass....5588
Sun Roof Glass and Associated Parts....5588
Removal....5588
Installation....5589
Sun Roof Deflector....5590
Removal....5590
Installation....5590
Sunshade....5590
Disassembled View....5590
Removal....5591
Installation....5591
Sun Roof Frame Complete Assembly....5592
Sun Roof Frame Complete Assembly and Associated Parts....5592
Removal....5592
Installation....5593
Disassembled View....5593
Disassembly....5593
Reassembly....5594
Sun Roof Drain Hose (Front Side)....5595
Sun Roof Drain Hose (Front Side) and Associated Parts....5595
Removal....5595
Installation....5595
Sun Roof Drain Hose (Rear Side)....5596
Sun Roof Drain Hose (Rear Side) and Associated Parts....5596
Removal....5596
Installation....5596
Sun Roof Switch....5597
General Description....5597
Removal....5597
Installation....5597
Sun Roof Motor....5598
Removal....5598
Installation....5598
Main Data and Specifications....5598
8J EXTERIOR / INTERIOR TRIM....5599
Service Precaution....5600
Dash Side Trim Panel....5601
Removal....5601
Installation....5601
Assist Grip....5601
Parts Location....5601
Removal and Installation....5601
Consoles....5602
Consoles and Associated Parts....5602
Removal....5602
Installation....5603
Front Door Trim Panel....5604
Front Door Trim Panel and Associated Parts....5604
Removal....5604
Installation....5607
Rear Door Trim Panel....5608
Rear Door Trim Panel and Associated Parts....5608
Removal....5608
Installation....5609
Door Mirror....5611
Door Mirror and Associated Parts....5611
Removal....5611
Installation....5611
Luggage Side and Quarter Upper Trim Cover (Long Wheel Base)....5612
Luggage Side, Quarter Upper Trim Cover and Associated Parts....5612
Removal....5612
Installation....5614
Luggage Side and Quarter Upper Trim Cover (Short Wheel Base)....5615
Luggage Side, Quarter Upper Trim Cover and Associated Parts....5615
Removal....5615
Installation....5617
Center Pillar and Roof Side Trim Cover (Long Wheel Base)....5618
Center Pillar, Roof Side Trim Cover and Associated Parts....5618
Removal....5618
Installation....5619
Roof Side Trim Cover (Short Wheel Base)....5620
Roof Side Trim Cover and Associated Parts....5620
Removal....5620
Installation....5620
Front Pillar Trim Cover....5621
Front Pillar Trim Cover and Associated Parts....5621
Removal....5621
Installation....5621
Center Pillar Assist Grip....5622
Parts Location....5622
Removal and Installation....5622
Assist Grip....5622
Parts Location....5622
Removal and Installation....5622
Fuel Filler Lid Opener Cable....5623
Fuel Filler Lid Opener Cable and Associated Parts....5623
Removal....5623
Installation....5624
Fuel Filler Door....5624
Parts Location....5624
Removal....5624
Installation....5624
Rocker Protector (Without Wheel Opening Extension)....5625
Rocker Protector (Without Wheel Opening Extension) and Associated Parts....5625
Removal....5625
Installation....5625
Wheel Opening Extension and Rocker Protector Assembly....5626
Wheel Opening Extension, Rocker Protector Assembly and Associated Parts....5626
Removal....5626
Installation....5627
Mud Flaps (With Wheel Opening Extension)....5629
Mud Flaps (With Wheel Opening Extension) and Associated Parts....5629
Removal....5629
Installation....5629
Ventilation Assembly....5630
Ventilation Assembly and Associated Parts....5630
Removal....5630
Installation....5630
Quarter Flipper Glass Assembly (S・W・B)....5631
Quarter Flipper Glass Assembly and Associated Parts....5631
Removal....5631
Installation....5631
Tailgate Trim Panel (LH)....5632
Tailgate Trim Panel (LH) and Associated Parts....5632
Removal....5632
Installation....5633
Tailgate Trim Panel (RH)....5634
Parts Location....5634
Removal....5634
Installation....5634
Luggage Floor Box....5635
Luggage Floor Box and Associated Parts....5635
Remove....5635
Installation....5635
Rope Hook Set....5635
Rope Hook Set and Associated Parts....5635
Removal....5635
Installation....5635
Power Door Mirror System....5636
General Description....5636
Door Mirror Switch Assembly (Control Switch, Folding Switch and Defogger Switch) Removal....5636
Installation....5636
Power Door Mirror....5636
General Description....5636
Removal and Installation....5636
Power Window System....5637
General Description....5637
Power Window Switch Removal and Installation....5637
Power Window Motor Removal and Installation....5638
Main Data and Specifications....5639
Sec.9 RESTRAINTS....5640
9A SEAT BELT SYSTEM....5640
Service Precaution....5640
Seat Belt....5641
Front Seat Belt and Associated Parts (Long Wheel Base)....5641
Removal....5641
Inspection....5641
Installation....5642
Front Seat Belt and Associated Parts (Short Wheel Base)....5643
Removal....5643
Inspection....5643
Installation....5644
Rear Seat Belt and Associated Parts (Long Wheel Base)....5645
Removal....5645
Inspection....5645
Installation....5646
Rear Seat Belt and Associated Parts (Short Wheel Base)....5647
Removal....5647
Inspection....5648
Installation....5648
Third Seat Belt and Associated Parts (Long Wheel Base)....5649
Removal....5649
Inspection....5650
Installation....5650
Front Seat Buckle Assembly....5651
Removal....5651
Installation....5651
Front Seat Buckle Assembly (W/Pretensioner)....5651
Removal....5651
Installation....5651
Rear Center Seat Belt Buckle Assembly....5652
Rear Center Seat Belt Buckle Assembly and Associated Parts....5652
Removal....5652
Installation....5652
Third Seat Belt Buckle and Lock Assembly....5653
Third Seat Belt Buckle and Lock Assembly and Associated Parts....5653
Removal....5653
Installation....5653
Rear Seat Lock Assembly....5654
Removal....5654
Installation....5654
Rear Seat Lock Assembly (Bench Type)....5654
Removal....5654
Installation....5654
Rear Seat Strikers....5655
Removal....5655
Installation....5655
Third Seat Striker....5655
Removal....5655
Installation....5655
Main Data and Specifications....5656
9J SUPPLEMENTAL RESTRAINT SYSTEM (SRS)....5657
Service Precaution....5657
General Description....5658
SRS Component And Wiring Location View....5660
Component Description....5660
Definitions....5663
Diagnosis....5664
SRS Connector Body Face Views....5665
Repairs And Inspections Required After An Accident....5665
On–Vehicle Service....5666
Air Bag Assembly Handling / Shipping / Scrapping....5667
Pretensioner Seat Belt Handling / Shipping / Scrapping.....5667
Special Tools....5682
Service Precautions for SRS Component Service....5686
SRS Connectors....5687
Sensing And Diagnostic Module (SDM)....5689
Service Precautions....5689
Removal....5689
Installation....5689
Driver Air Bag Assembly....5691
Service Precautions....5691
Removal....5691
Installation....5692
Steering Wheel....5693
Service Precautions....5693
Removal....5693
Installation....5694
SRS Coil Assembly....5695
Service Precautions....5695
Removal....5695
Installation....5697
SRS Coil Replacement Procedure....5698
Removal....5698
How to Disconnect the horn terminal....5699
How to Connect Horn Terminal....5699
Installation....5700
Steering Column....5700
Service Precautions....5700
Removal....5700
Installation....5702
Passenger Air Bag Assembly....5704
Service Precautions....5704
Removal....5704
Installation....5704
Pretensioner Seat Belt (If so equipped)....5705
Service Precaution....5705
Parts Location....5705
Removal....5705
Installation....5705
Main Data and Specifications....5706
9J1 RESTRAINT CONTROL SYSTEM....5707
Service Precaution....5707
Diagnostic Information....5708
System Schematic....5710
SRS Diagnostic System Check....5710
Chart A SDM Integrity Check....5712
Chart B “AIR BAG” Warning Lamp Comes “ON” Steady....5714
Chart C “AIR BAG” Warning Lamp Does Not Come “ON” Steady....5716
DTC 15 Passenger Deployment Loop Resistance High....5719
DTC 16 Passenger Deployment loop Resistance Low....5721
DTC 17 Passenger Deployment Loop Open....5723
DTC 18 Passenger Deployment Loop Short To Ground....5725
DTC 19 Passenger Deployment Loop Short To B+....5727
DTC 21 Driver Deployment Loop Resistance High....5729
DTC 22 Driver Deployment Loop Resistance Low....5732
DTC 24 Driver Deployment Loop Short To Ground....5735
DTC 25 Driver Deployment Loop Short To B+....5737
DTC 26 Driver Deployment Loop Open....5739
DTC 51 Air Bag Deployment Event Commanded....5741
DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy Reserves Out Of Range....5743
DTC 61 Warning Lamp Circuit Failure....5745
DTC 71 Internal SDM Fault....5747
DTC 29 Passenger Pretensioner Loop Short To Ground....5749
DTC 31 Passenger Pretensioner Loop Resistance High....5751
DTC 32 Passenger Pretensioner loop Resistance Low....5753
DTC 33 Passenger Pretensioner Loop Short To Voltage....5755
DTC 34 Passenger Pretensioner Loop Open....5757
DTC 41 Driver Pretensioner Loop Resistance High....5759
DTC 42 Driver Pretensioner Loop Resistance Low....5761
DTC 44 Driver Pretensioner Loop Open....5763
DTC 45 Driver Pretensioner Loop Short To Ground....5765
DTC 46 Driver Pretensioner Loop Short To Voltage....5767
DTC 52 Pretensioner Deployment Event Commanded....5769
Sec.10 CONTROL SYSTEM....5771
10A CRUISE CONTROL SYSTEM....5771
Service Precaution....5771
General Description....5771
Diagnosis....5772
Brake Switch....5772
Removal....5772
Installation....5772
Adjustment....5773
Clutch Switch....5773
Removal and Installation....5773
Adjustment....5773
Starter Switch....5774
Removal....5774
Installation....5774
Cruise Control Main Switch....5775
Removal....5775
Installation....5775
Cruise Control Switch (Combination Switch)....5775
Removal and Installation....5775
Cruise Control Unit....5776
Removal....5776
Installation....5776
Cruise Actuator....5777
Actuator Cable Diagram (LHD)....5777
Actuator Cable Diagram (RHD)....5777
Removal....5778
Installation....5778
Mode Switch....5778
Removal and Installation....5778
2000 MODEL....0
UBS....5779
Sec.0 GENERAL INFORMATION....5792
0A GENERAL INFORMATION....5792
GENERAL REPAIR INSTRUCTIONS....5793
HOW TO USE THIS MANUAL....5794
IDENTIFICATION....5797
LIFTING INSTRUCTIONS....5799
TORQUE SPECIFICATIONS....5801
RECOMMENDED LIQUID GASKET....5802
RECOMMENDED THREAD LOCKING AGENTS....5802
ABBREVIATIONS CHARTS....5803
0B MAINTENANCE AND LUBRICATION....5805
MAINTENANCE SCHEDULE....5806
RECOMMENDED FLUIDS, LUBRICANTS AND FUELS....5811
OIL VISCOSITY CHART....5814
Sec.1 HEATING AND VENTILATION....5817
1A HEATING AND VENTILATION....5817
GENERAL DESCRIPTION....5818
HEATER....5818
CONTROL LEVER ASSEMBLY....5819
VENTILATION....5819
AIR SELECT KNOB....5820
AIR SOURCE SELECT LEVER....5820
FAN CONTROL KNOB....5820
TEMPERATURE CONTROL KNOB....5820
CERAMIC HEATER....5821
ON-VEHICLE SERVICE....5822
HEATER UNIT....5822
HEATER CORE AND/OR MODE DOOR....5824
HEATER MODE CONTROL LINK UNIT....5826
HEATER TEMPERATURE CONTROL LINK UNIT....5828
BLOWER ASSEMBLY....5830
BLOWER LINK UNIT AND/OR MODE DOOR....5832
BLOWER MOTOR....5834
REAR HEATER DUCT, DEFROSTER NOZZLE AND VENTILATION DUCT....5836
CENTER AND/OR SIDE VENT....5838
CONTROL LEVER ASSEMBLY AND/OR CONTROL CABLES....5840
CONTROL PANEL ILLUMINATION BULB....5843
RESISTOR....5844
CERAMIC HEATER AND/OR FULL HOT SWITCH....5846
1B AIR CONDITIONING....5849
GENERAL DESCRIPTION....5851
AIR CONDITIONING REFRIGERANT CYCLE CONSTRUCTION....5851
COMPRESSOR....5852
MAGNETIC CLUTCH....5853
RECEIVER/DRIER....5853
DUAL PRESSURE SWITCH....5854
TRIPLE PRESSURE SWITCH....5854
EXPANSION VALVE....5854
EVAPORATOR....5855
ELECTRONIC THERMOSTAT....5855
REFRIGERANT LINE....5855
SERVICE CHARGE VALVES....5855
AIR CONDITIONING PARTS....5856
ON-VEHICLE SERVICE....5861
PRECAUTIONS FOR REPLACEMENT OR REPAIR OF AIR CONDITIONING PARTS....5861
Compressor Assembly and Associated Parts....5871
CONDENSER ASSEMBLY (LHD V6 WITHOUT CONDENSER FAN)....5881
CONDENSER FAN MOTOR....5883
RECEIVER/DRIER....5885
PRESSURE SWITCH....5887
EVAPORATOR ASSEMBLY....5890
EVAPORATOR CORE AND/OR EXPANSION VALVE....5892
ELECTRONIC THERMOSTAT....5895
A/C SWITCH AND ILLUMINATION BULB....5896
REFRIGERANT LINE....5897
REAR COOLER PARTS....5899
FULL AUTOMATIC AIR CONDITIONING SYSTEM....5908
GENERAL DESCRIPTION....5908
Full Automatic Air Conditioner Parts Configuration....5908
CIRCUIT DIAGRAM....5910
FUNCTIONS AND FEATURES....5922
FULL AUTOMATIC AIR CONDITIONER BLOCK DIAGRAM....5923
AIR CONDITIONING PARTS....5924
Control Panel Layout....5928
Air Control Functions....5929
OPERATION AND FUNCTIONS OF CONTROL PANEL SWITCHES....5930
OVERVIEW OF CONSTRUCTION, MOVEMENT AND CONTROL OF MAJOR PARTS OF FULL AUTOMATIC AIR CONDITIONER SYSTEM....5932
OVERVIEW OF AUTOMATIC CONTROL OF FULL AUTOMATIC AIR CONDITIONER....5936
TROUBLESHOOTING....5940
Troubleshooting, Its Overview and Procedures....5940
Performance and Movement checklist for Automatic Air Conditioner Related Parts....5943
TROUBLESHOOTING WITH SELF-DIAGNOSIS FUNCTION....5945
INSPECTION BY FAILED LOCATION....5948
Inspection of the Sensors....5948
Inspection of the Intake Actuator System....5952
Inspection of the Mix Actuator System....5955
Inspection of the Mode Actuator System....5958
Inspection of the Fan Motor System....5961
Inspection of the Magnet Clutch System....5966
Inspection of the Air Conditioner Room Temperature Setup System....5971
INDIVIDUAL INSPECTION....5972
ON-VEHICLE SERVICE....5974
Power Transistor....5974
Automatic Heater/Air Conditioner Control Unit....5974
In Car Sensor....5975
Ambient Sensor....5975
Sun Sensor....5976
Electronic Thermostat....5976
Mode Actuator....5977
MIX Actuator....5977
Intake Actuator....5978
1D COMPRESSOR OVERHAUL....5979
GENERAL DESCRIPTION....5980
GENERAL INFORMATION....5982
COMPRESSOR OIL....5982
SERVICE PROCEDURE....5984
DKV-14D TYPE COMPRESSOR....5984
DKS-15CH TYPE COMPRESSOR....5988
HD6 TYPE COMPRESSOR....5996
Sec.2 SERVICE INFORMATION....6005
00 SERVICE INFORMATION....6005
TROUBLESHOOTING....6007
GENERAL INFORMATION....6008
GENERAL TROUBLESHOOTING....6008
POWER STEERING SYSTEM....6011
POWER STEERING PUMP....6012
STEERING COLUMN....6013
MAIN DATA AND SPECIFICATIONS....6015
SERVICE STANDARD....6016
SERVICING....6017
FIXING TORQUE....6019
SPECIAL TOOLS....6023
2A FRONT END ALIGNMENT....6025
GENERAL DESCRIPTION....6026
DEFINITION OF TERMS....6026
ON-VEHICLE SERVICE....6027
INSPECTION....6027
TRIM HEIGHT ADJUSTMENT....6027
CASTER ADJUSTMENT....6028
CAMBER ADJUSTMENT....6028
TOE-IN ADJUSTMENT....6029
MAXIMUM STEERING ANGLE ADJUSTMENT....6029
Sec.3 FRONT SUSPENSION....6111
3C FRONT SUSPENSION....6111
GENERAL DESCRIPTION....6112
ON-VEHICLE SERVICE....6113
SHOCK ABSORBER....6113
STABILIZER BAR....6115
TORSION BAR....6117
KNUCKLE....6120
UPPER CONTROL ARM....6124
LOWER CONTROL ARM....6128
UPPER BALL JOINT....6132
LOWER BALL JOINT....6135
3D REAR SUSPENSION; COIL SPRING....6138
GENERAL DESCRIPTION....6139
ON-VEHICLE SERVICE....6140
COIL SPRING....6140
SHOCK ABSORBER....6143
TRAILING LINK....6145
CENTER LINK....6147
LATERAL ROD....6149
STABILIZER BAR....6152
3E WHEELS AND TIRES....6154
GENERAL DESCRIPTION....6155
ON-VEHICLE SERVICE....6156
WHEELS....6156
UNIT REPAIR....6157
TIRES....6157
WHEELS....6158
GENERAL BALANCE PROCEDURE....6158
BALANCING WHEEL AND TIRE....6159
Sec.4 DRIVELINE/AXLE....6160
4A1 DIFFERENTIAL (FRONT)....6160
Service Precaution....6160
Front Drive Axle....6161
Diagnosis....6161
Pinion Shaft Oil Seal....6162
Pinion Shaft Oil Seal and Associated Parts....6162
Removal....6162
Inspection and Repair....6163
Installation....6163
Front Drive Axle Assembly....6164
Front Drive Axle Assembly and Associated Parts....6164
Removal....6164
Installation....6166
Differential Assembly....6168
Disassembled View....6168
Disassembly....6169
Reassembly....6171
Differential Cage Assembly....6180
Disassembled View....6180
Disassembly....6180
Inspection and Repair....6181
Reassembly....6182
Main Data and Specifications....6184
Special Tools....6187
4A2A DIFFERENTIAL (Rear 220mm)....6189
Service Precaution....6189
General Description....6190
Diagnosis....6191
Axle Housing....6192
Axle Housing and Associated Parts....6192
Removal....6192
Oil Seal Replacement....6193
Installation....6193
Axle Shaft....6194
Axle Shaft and Associated Parts....6194
Removal....6194
Inspection and Repair....6195
Oil Seal Replacement....6196
Installation....6196
Pinion Oil Seal....6197
Pinion Oil Seal and Associated Parts....6197
Removal....6197
Inspection and Repair....6198
Installation....6198
Differential Assembly....6199
Differential Assembly and Associated Parts....6199
Removal....6199
Installation....6200
Disassembled View....6201
Disassembly....6202
Reassembly....6204
Differential Cage Assembly....6212
Disassembled View....6212
Disassembly....6212
Inspection and Repair....6213
Reassembly....6214
Limited Slip Differential....6216
Disassembled View....6216
Disassembly....6217
Inspection and Repair....6217
Reassembly....6219
Main Data and Specifications....6223
Special Tools....6225
4A2B DIFFERENTIAL (REAR 244mm)....6227
Service Precaution....6227
General Description....6229
Diagnosis....6230
Axle Housing....6231
Axle Housing and Associated Parts....6231
Removal....6231
Oil Seal Replacement....6232
Installation....6232
Axle Shaft....6233
Axle Shaft and Associated Parts....6233
Removal....6233
Inspection and Repair....6234
Oil Seal Replacement....6235
Installation....6235
Pinion Oil Seal....6236
Pinion Oil Seal and Associated Parts....6236
Removal....6236
Inspection and Repair....6237
Installation....6237
Differential Assembly....6238
Differential Assembly and Associated Parts....6238
Removal....6238
Installation....6239
Disassembled View....6240
Disassembly....6241
Reassembly....6243
Differential Cage Assembly....6250
Disassembled View....6250
Disassembly....6251
Inspection and Repair....6251
Reassembly....6252
Limited Slip Differential....6254
Disassembled View....6254
Disassembly....6255
Inspection and Repair....6255
Reassembly....6257
Main Data and Specifications....6261
Special Tools....6263
4B1 DRIVELINE CONTROL SYSTEM (SHIFT ON THE FLY)....6265
Service Precaution....6265
Shift on the Fly System (Lever Type)....6266
Outline of Shift on the Fly System (Lever Type)....6266
Shift on the Fly Vacuum Piping and Electric Equipment (For Lever Control Type)....6267
Vacuum Piping Diagram....6267
Inspection and Repair....6268
Shift on the Fly System (Push Button Type)....6271
Outline of Shift on the Fly System (Push Button Type)....6271
Functions of Indicator Lamp....6275
Diagnosis....6275
Front Axle Diagnosis....6294
Shift on the Fly Vacuum Piping and Electric Equipment (For Push Button Type)....6296
Vacuum Piping Diagram....6296
Inspection and Repair....6297
4WD Control Unit (For Push Button Type)....6300
4WD Control Unit Associated Parts....6300
Removal....6301
Installation....6301
4B2 DRIVELINE CONTROL SYSTEM (TOD)....6303
Service Precaution....6303
General Description....6304
System Components....6306
Parts Location....6306
Functions of Indicator Lamp....6310
Diagnosis....6315
Basic Diagnostic Flow Chart....6319
Parts Location (RHD 6VE1)....6320
Circuit Diagram–1 (RHD 6VE1)....6324
Connector List....6336
Checking Failed Pin....6338
Checking Failed TOD Control Unit Pin....6341
Diagnostic Trouble Codes....6345
Diagnosis from Trouble Codes....6346
Trouble Diagnosis Depending on The Status of TOD Indicator....6376
Diagnosis from Symptom....6416
4C DRIVE SHAFT SYSTEM....6426
Service Precaution....6427
General Description....6427
Diagnosis....6428
Rear Axle Shaft....6429
Rear Axle Shaft and Associated Parts....6429
Removal....6429
Inspection and Repair....6430
Oil Seal Replacement....6431
Installation....6431
Special Tools....6433
Front Hub and Disc (with Shift on the Fly)....6434
Disassembled View....6434
Disassembly....6434
Inspection and Repair....6435
Reassembly....6436
Front Hub and Disc with Manual Locking Hub....6439
Disassembled View....6439
Disassembly....6439
Inspection and Repair....6441
Reassembly....6441
Main Data and Specifications....6445
Special Tools....6446
Front Drive Shaft Joint....6447
Front Drive Shaft Joints Replacement....6447
Front Axle Drive Shaft....6448
Front Axle Drive Shaft and Associated Parts....6448
Disassembly....6449
Inspection and Repair....6450
Bushing Replacement....6450
Reassembly....6451
Shift On The Fly System....6453
Shift On The Fly System and Associated Parts....6453
Disassembly....6453
Inspection and Repair....6455
Main Data and Specifications....6460
Special Tools....6461
Front Propeller Shaft....6462
General Description....6462
Front Propeller Shaft and Associated Parts....6463
Removal....6463
Installation....6464
Disassembly (Except TOD 4×4)....6465
Universal Joint Disassembly....6466
Inspection and Repair....6467
Universal Joint Reassembly....6470
Reassembly (Except TOD 4×4)....6471
Main Data and Specifications....6472
Rear Propeller Shaft....6473
General Description....6473
Rear Propeller Shaft and Associated Parts....6473
Removal....6474
Installation....6474
Disassembly....6475
Universal Joint Disassembly....6476
Inspection and Repair....6477
Universal Joint Reassembly....6478
Reassembly....6479
Main Data and Specifications....6480
4D1 TRANSFER CASE (STANDARD TYPE)....6481
Service Precaution....6481
General Description....6482
Transfer Rear Oil Seal....6488
Removal....6488
Installation....6488
Transfer Case Assembly....6489
Removal....6489
Installation....6490
Transfer Rear Cover Assembly (4WD Switch Model)....6491
Transfer Rear Cover Assembly and Associated Parts....6491
Removal....6492
Installation....6493
Disassembly....6496
Inspection and Repair....6497
Reassembly....6497
Transfer Rear Cover Assembly (Except 4WD Switch Model)....6499
Transfer Rear Cover Assembly and Associated Parts....6499
Removal....6500
Installation....6500
Disassembly....6503
Inspection and Repair....6504
Reassembly....6504
Detent, Shift Arm, and Interlock Pin....6506
Disassembled View....6506
Disassembly....6506
Inspection and Repair....6508
Reassembly....6508
Transfer Case Assembly....6510
Disassembled View....6510
Disassembly....6511
Inspection and Repair....6513
Reassembly....6517
Main Data and Specifications....6523
Special Tools....6526
4D2 TRANSFER CASE (TOD)....6527
Service Precaution....6527
Transfer Case Assembly....6528
Removal....6528
Installation....6529
Transfer Rear Oil Seal....6531
Transfer Rear Oil Seal and Associated Parts....6531
Removal....6531
Installation....6531
TOD ECU....6533
Removal....6533
Installation....6533
Unit Repair....6534
Inspection....6534
Transfer Case....6535
Disassembled View....6535
Disassembly....6535
Reassembly....6536
Transfer Cover Assembly....6538
Disassembled View....6538
Disassembly....6538
Reassembly....6540
Transfer Case Assembly Clutch Pack and Clutch Cam....6542
Disassembled View....6542
Disassembly....6542
Sprocket and Mechanical Lock....6544
Disassembled View....6544
Disassembly....6544
Output Shafts and Shift Control Shaft....6546
Disassembled View....6546
Disassembly....6547
Transfer Case....6549
Disassembled View....6549
Disassembly....6550
Inspection and Repair....6552
Transfer Case....6556
Disassembled View....6556
Reassembly....6556
Output Shafts and Shift Control Shaft....6560
Disassembled View....6560
Reassembly....6560
Sprocket and Mechanical Lock....6563
Disassembled View....6563
Reassembly....6563
Clutch Pack and Clutch Cam....6565
Disassembled View....6565
Reassembly....6565
Main Data and Specifications....6567
Special Tools....6569
Sec.5 BRAKES....6570
5A BRAKE CONTROL SYSTEM....6570
Service Precaution....6571
General Description....6572
System Components....6572
Electronic Hydraulic Control Unit (EHCU)....6572
ABS Warning Light....6573
Wheel Speed Sensor....6573
G-Sensor....6573
Normal and Anti-lock Braking....6573
Brake Pedal Travel....6573
Acronyms and Abbreviations....6573
General Diagnosis....6574
General Information....6574
ABS Service Precautions....6574
Computer System Service Precautions....6574
General Service Precautions....6574
Note on Intermittents....6574
Test Driving ABS Complaint Vehicles....6575
“ABS” Warning Light....6575
Normal Operation....6575
Basic Diagnostic Flow Chart....6575
Basic Inspection Procedure....6576
Tech 2 Scan Tool....6577
Getting Started....6578
Operating Procedure....6579
Data List....6580
EHCU Connector Pin-out Checks....6581
Circuit Diagram (LHD model / 6VD1 and 4JG2)....6582
Circuit Diagram (LHD model / 4JG2)....6583
Circuit Diagram (LHD model / 4JG2)....6584
Circuit Diagram (LHD model / 6VD1)....6585
Circuit Diagram (LHD model / 6VD1)....6586
Connector List (LHD model)....6587
Part Location (LHD model)....6589
Circuit Diagram (RHD model / 6VD1 and 4JG2)....6590
Circuit Diagram (RHD model / 4JG2)....6591
Circuit Diagram (RHD model / 4JG2)....6592
Circuit Diagram (RHD model / 6VD1)....6593
Circuit Diagram (RHD model / 6VD1)....6594
Circuit Diagram (RHD model / 6VE1 and 4JX1)....6595
Circuit Diagram (RHD model / 4JX1)....6596
Circuit Diagram (RHD model / 4JX1)....6597
Circuit Diagram (RHD model / 6VE1)....6598
Circuit Diagram (RHD model / 6VE1)....6599
Connector List (RHD model)....6600
Part Location (RHD model)....6603
Symptom Diagnosis....6604
Chart A–1 ABS Works Frequently But Vehicle Does Not Decelerate....6604
Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)....6605
Chart A-2 Uneven Braking Occurs While ABS Works....6605
Chart A-3, TA-3 The Wheels Are Locked....6605
Chart A-4 Brake Pedal Feed Is Abnormal....6606
Chart A-5, TA-5 Braking Sound (From EHCU) Is Heard While Not Braking....6607
Diagnostic Trouble Codes....6608
Diagnosis By “ABS” Warning Light Illumination Pattern....6609
Diagnostic Trouble Codes (DTCs)....6609
Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated.....6612
Chart B-2 EHCU Abnormality (DTC 14)....6612
Chart B-3 Power Voltage Drop (DTC 15)....6613
Chart B-4 CLASS-2 Communication Line Abnormality (DTC 16)....6613
Chart B-5 G-Sensor Circuit (DTC 21)....6614
Chart B-6 Abnormal Transmission Input (DTC 23)....6615
Chart B-7 Transfer Monitor (DTC 24)....6616
Chart B-8 EHCU Pump Motor And Motor Relay Circuit (DTC 32)....6616
Chart B-9 EHCU Pump Valve And Valve Relay Circuit (DTC 35)....6616
Chart B-10 FL Isolation Solenoid Valve Abnormality (DTC 41)....6617
Chart B-11 FL Dump Solenoid Valve Abnormality (DTC 42)....6617
Chart B-12 FR Isolation Solenoid Valve Abnormality (DTC 43)....6617
Chart B-13 FR Dump Solenoid Valve Abnormality (DTC 44)....6618
Chart B-14 Rear Isolation Solenoid Valve Abnormality (DTC 45)....6618
Chart B-15 Rear Dump Solenoid Valve Abnormality (DTC 46)....6618
Chart B-16 FL Speed Sensor Disconnection (DTC 51)....6619
Chart B-17 FR Speed Sensor Disconnection (DTC 52)....6619
Chart B-18 RL Speed Sensor Disconnection (DTC 53)....6620
Chart B-19 RR Speed Sensor Disconnection (DTC 54)....6620
Chart B-20 FL Speed Sensor Short Circuit (DTC 61)....6621
Chart B-21 FR Speed Sensor Short Circuit (DTC 62)....6622
Chart B-22 RL Speed Sensor Short Circuit (DTC 63)....6623
Chart B-23 RR Speed Sensor Short Circuit (DTC 64)....6624
Chart B-24 Sensor Signal Input Abnormality (DTC 65)....6625
Sensor Signal Abnormality Criteria using TECH 2....6625
Unit Inspection Procedure....6626
Chart C-1-1 FL Sensor Output Inspection Procedure....6626
Chart C-1-2 FR Sensor Output Inspection Procedure....6627
Chart C-1-3 RL Sensor Output Inspection Procedure....6627
Chart C-1-4 RR Sensor Output Inspection Procedure....6628
Chart TC-1 Sensor Output Inspection Procedure (Use TECH 2)....6628
Chart C-2 Transmission Input Inspection Procedure....6629
Chart TC-2 Transmission Input Inspection Procedure (Use TECH 2)....6630
Special Tools....6631
5B ANTI-LOCK BRAKE SYSTEM....6632
Service Precaution....6632
Electronic Hydraulic Control Unit....6633
Electronic Hydraulic Control Unit and Associated Parts....6633
Removal....6633
Installation....6633
G-Sensor....6634
Removal....6634
Inspection and Repair....6634
Installation....6634
Front Wheel Speed Sensor....6635
Front Wheel Speed Sensor and Associated Parts....6635
Removal....6635
Inspection and Repair....6636
Installation....6636
Rear Wheel Speed Sensor....6637
Rear Wheel Speed Sensor and Associated Parts....6637
Removal....6637
Inspection and Repair....6637
Installation....6637
5C POWER ASSISTED BRAKE SYSTEM....6638
SERVICE PRECAUTION....6639
BRAKE SYSTEM DIAGNOSIS....6640
TROUBLESHOOTING....6642
MAIN DATA AND SPECIFICATIONS....6644
SERVICE STANDARD....6645
SERVICING....6646
FIXING TORQUE....6655
SPECIAL TOOLS....6658
GENERAL DESCRIPTION....6659
MASTER CYLINDER....6659
VACUUM BOOSTER....6660
DISC BRAKES....6661
ON-VEHICLE SERVICE....6662
BRAKE HOSE REPLACEMENT....6662
BRAKE PIPE REPLACEMENT....6664
P & B VALVE....6665
P & B VALVE REPLACEMENT....6666
LOAD SENSING PROPORTIONING VALVE (LSPV)....6667
BRAKE PEDAL REPLACEMENT....6671
STOPLIGHT SWITCH REPLACEMENT....6673
FLUID RESERVOIR TANK....6675
MASATER CYLINDER ASSEMBLY....6676
VACUUM BOOSTER ASSEMBLY....6678
EXTERIOR COMPONENTS....6681
FRONT DISC BRAKE....6684
BRAKE PADS REPLACEMENT....6684
CALIPER REPLACEMENT....6687
REBUILDING THE CALIPER....6690
REAR DISC BRAKE....6693
BRAKE PADS REPLACEMENT....6693
CALIPER REPLACEMENT....6696
REBUILDING THE CALIPER....6699
UNIT REPAIR....6702
MASTER CYLINDER....6702
VACUUM BOOSTER....6704
5D PARKING BRAKES....6705
SERVICE PRECAUTION....6705
MAIN DATA AND SPECIFICATIONS....6706
SERVICE STANDARD....6706
SERVICING....6707
FIXING TORQUE....6709
GENERAL DESCRIPTION....6710
ON-VEHICLE SERVICE....6711
PARKING BRAKE LEVER REPLACEMENT....6711
PARKING BRAKE CABLE....6713
Sec.6 ENGINE(6VD1/6VE1)....6716
6A ENGINE MECHANICAL....6716
Service Precaution....6717
General Description....6718
Engine Diagnosis....6719
Cylinder Head Cover LH....6733
Removal....6733
Installation....6734
Cylinder Head Cover RH....6736
Removal....6736
Installation....6737
Common Chamber....6739
Removal....6739
Installation....6739
Exhaust Manifold LH....6741
Removal....6741
Installation....6741
Exhaust Manifold RH....6742
Removal....6742
Installation....6742
Crankshaft Pulley....6743
Removal....6743
Installation....6743
Timing Belt....6744
Removal....6744
Installation....6745
Camshaft....6748
Removal....6748
Installation....6748
Cylinder Head....6752
Removal....6752
Installation....6752
Valve Stem Oil Controller , Valve Spring and Valve Guide....6754
Removal....6754
Installation....6754
Piston, Piston Ring and Connecting Rod....6755
Removal....6755
Installation....6756
Crankshaft and Main Bearings....6757
Removal....6757
Installation....6758
Rear Oil Seal....6762
Removal....6762
Installation....6762
Engine Assembly....6763
Removal....6763
Installation....6763
Cylinder Head....6767
Cylinder Head and Associated Parts....6767
Disassembly....6767
Clean....6768
Inspection and Repair....6768
Reassembly....6768
Valve Spring, Oil Controller, Valve, Valve Guide....6771
Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts....6771
Disassembly....6771
Inspection and Repair....6772
Reassembly....6775
Valve Clearance Adjustments....6776
Camshaft....6778
Camshaft and Associated Parts....6778
Disassembly....6778
Inspection and Repair....6779
Reassembly....6781
Crankshaft....6784
Crankshaft and Associated Parts....6784
Disassembly....6784
Inspection and Repair....6785
Inspection and Repair....6786
Reassembly....6788
Piston and Connecting Rod....6792
Piston, Connecting Rod and Associate Parts....6792
Disassembly....6792
Inspection and Repair....6793
Reassembly....6797
Cylinder Block....6800
Cylinder Block and Associated Parts....6800
Disassembly....6800
Inspection and Repair....6801
Reassembly....6802
Main Data and Specification....6805
Special Tool....6811
6B ENGINE COOLING....6813
Service Precaution....6813
General Description....6814
Diagnosis....6817
Draining and Refilling Cooling System....6818
Water Pump....6819
Water Pump and Associated Parts....6819
Removal....6819
Inspection....6819
Installation....6819
Thermostat....6820
Thermostat and Associated Parts....6820
Removal....6820
Inspection....6820
Installation....6820
Radiator....6821
Radiator and Associated Parts....6821
Removal....6821
Inspection....6822
Installation....6823
Drive Belt and Cooling Fan....6824
Drive Belt and Associated Parts....6824
Inspection....6824
Installation....6824
Main Data and Specifications....6825
Special Tool....6826
6C ENGINE FUEL....6827
Service Precaution....6827
General Description....6828
Fuel Metering....6829
Fuel Filter....6830
Fuel Filter and Associated Parts....6830
Removal....6830
Inspection....6830
Installation....6831
Inspection....6831
In‐Tank Fuel Filter....6831
Fuel Pump Flow Test....6831
Fuel Pump....6832
Fuel Pump and Associated Parts....6832
Removal....6832
Installation....6832
Fuel Pump Relay....6833
General Description....6833
Fuel Tank....6833
Fuel Tank and Associated Parts....6833
Removal....6833
Installation....6834
Fuel Tube / Quick – Connect Fittings....6834
Precautions....6834
Cautions During Work....6834
Removal....6834
Reuse of Quick–Connector....6836
Assembling Advice....6836
Fuel Gauge Unit....6837
Fuel Gauge Unit and Associated Parts....6837
Removal....6837
Installation....6837
Fuel Filler Cap....6838
General Description....6838
Inspection....6838
Main Data and Specifications....6838
6D1 ENGINE ELECTRICAL....6839
Service Precaution....6839
Battery....6840
General Description....6840
Diagnosis....6840
Battery Charging....6841
Jump Starting....6841
Battery Removal....6842
Battery Installation....6842
Main Data and Specifications....6843
6D2 IGNITION SYSTEM....6845
Service Precaution....6845
General Description....6846
Diagnosis....6846
Ignition Coil....6847
Removal....6847
Inspection and Repair....6847
Installation....6847
Spark Plug....6848
Removal....6848
Inspection and Repair....6848
Installation....6848
Crankshaft Angle Sensor....6849
Removal....6849
Installation....6849
Main Data and Specifications....6850
6D3 STARTING AND CHARGING SYSTEM....6851
Service Precaution....6851
Starting System....6852
General Description....6852
Diagnosis....6854
Starter....6855
Removal....6855
Installation....6855
Disassembled View....6856
Disassembly....6857
Inspection and Repair....6859
Reassembly....6863
Main Data and Specifications....6865
Charging System....6868
General Description....6868
General On–Vehicle Inspection....6868
Generator....6869
Removal....6869
Inspection....6869
Installation....6869
Disassembled View....6870
Disassembly....6871
Inspection and Repair....6873
Reassembly....6874
Bench Test....6875
Main Data and Specifications....6876
6E ENGINE DRIVEABILITY AND EMISSIONS....6877
Specifications....6881
Tightening Specifications....6881
Vehicle Type Specifications....6881
Diagrams and Schematics....6882
PCM Wiring Diagram (1 of 11)....6882
PCM Wiring Diagram (2 of 11) For EC, THAILAND, SOUTH EAST ASIA, LATIN AMERICA, GULF, SAUDI, CHINA.....6883
PCM Wiring Diagram (3 of 11) For SOUTH AFRICA and EXP.....6884
PCM Wiring Diagram (4 of 11)....6885
PCM Wiring Diagram (5 of 11)....6886
PCM Wiring Diagram (6 of 11) For AUSTRALIA, THAILAND, SOUTH EAST ASIA, LATIN AMERICA, GULF, SAUDI, LATIN AMERICA.....6887
PCM Wiring Diagram (7 of 11) For EC.....6888
PCM Wiring Diagram (8 of 11) For EXPORT and SOUTH AFRICA.....6889
PCM Wiring Diagram (9 of 11) Except EXP and SOUTH AFRICA....6890
PCM Wiring Diagram (10 of 11) For EXPORT and SOUTH AFRICA....6891
PCM Wiring Diagram (11 of 11)....6892
PCM Pinouts....6893
PCM Pinout Table, 32-Way Red Connector – Row “A”....6893
PCM Pinout Table, 32-Way Red Connector – Row “B”....6895
PCM Pinout Table, 32-Way White Connector – Row “C” (For EC)....6896
PCM Pinout Table, 32-Way White Connector – Row “C” (For except EC)....6897
PCM Pinout Table, 32-Way White Connector ‐ Row “D” (For except EXPORT and SOUTH AFRICA)....6898
PCM Pinout Table, 32-Way White Connector ‐ Row “D” (For EXPORT and SOUTH AFRICA)....6899
PCM Pinout Table, 32-Way Blue Connector ‐ Row “E” (For except EXPORT and SOUTH AFRICA)....6900
PCM Pinout Table, 32-Way Blue Connector ‐ Row “E” (For EXPORT and SOUTH AFRICA)....6902
PCM Pinout Table, 32-Way Blue Connector ‐ Row “F”....6903
Component Locators....6904
Engine Component Locator (This illustration is based on RHD model.)....6904
Engine Component Locator Table....6905
Engine Component Locator Table....6907
Undercarriage Component Locator....6908
Undercarriage Component Locator Table (Automatic Transmission)....6908
Undercarriage Component Locator Table (Manual Transmission)....6909
Fuse and Relay Panel (Underhood Electrical Center)....6909
Sensors and Miscellaneous Component Locators....6910
Diagnosis....6913
Strategy-Based Diagnostics....6913
DTC Stored....6913
No DTC....6913
No Matching Symptom....6913
Intermittents....6913
No Trouble Found....6913
Verifying Vehicle Repair....6913
General Service Information....6914
OBD Serviceablity Issues....6914
Maintenance Schedule....6914
Visual / Physical Engine Compartment Inspection....6914
Basic Knowledge of Tools Required....6914
Serial Data Communications....6914
Class II Serial Data Communications....6914
On-Board Diagnostic (OBD)....6915
On-Board Diagnostic Tests....6915
Comprehensive Component Monitor Diagnostic Operation....6915
Common OBD Terms....6916
The Diagnostic Executive....6916
DTC Types....6917
Verifying Vehicle Repair....6918
Reading Diagnostic Trouble Codes Using A Tech 2....6918
Tech 2....6919
Tech 2 Features....6919
Getting Started....6920
Operating Procedure (For Example)....6920
DTC Modes....6921
DTC Information Mode....6922
Injector Balance Test....6922
EGR Control Test....6923
Idle Air Control System Test....6924
Primary System-Based Diagnostic....6926
Primary System-Based Diagnostic....6926
Fuel Control Heated Oxygen Sensor....6926
HO2S Heater....6926
Fuel Trim System Monitor Diagnostic Operation....6926
Fuel Trim System Monitor Diagnostic Operation....6926
Fuel Trim Cell Diagnostic Weights....6926
On-Board Diagnostic (OBD) System Check....6927
A/C Clutch Control Circuit Diagnosis....6930
Electronic Ignition System Diagnosis....6936
Fuel Metering System Check....6936
Idle Air Control (IAC) Valve....6936
Fuel System Pressure Test....6936
Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure....6936
Knock Sensor Diagnosis....6941
Powertrain Control Module (PCM) Diagnosis....6941
Multiple PCM Information Sensor DTCS Set....6941
Exhaust Gas Recirculation (EGR) Diagnosis (For except EXPORT and SOUTH AFRICA)....6944
Engine Tech 2 Data Definitions and Ranges....6944
Typical Scan Data Values....6946
No Malfunction Indicator Lamp (MIL)....6950
Malfunction Indicator Lamp (MIL) “ON” Steady....6953
Engine Cranks But Will Not Run....6955
Fuel System Electrical Test....6961
Fuel System Diagnosis....6964
Idle Air Control (IAC) System Check....6969
Knock Sensor (KS) System Check (Engine Knock, Poor Performance, or Poor Economy)....6971
Exhaust Gas Recirculation (EGR) System Check....6973
Manifold Absolute Pressure (MAP) Output Check....6975
PCM Diagnostic Trouble Codes....6977
Diagnostic Trouble Code (DTC) P0101 MAF System Performance....6980
Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency....6983
Diagnostic Trouble Code (DTC) P0103 MAF Sensor Circuit High Frequency....6986
Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage....6988
Diagnostic Trouble Code (DTC) P0108 MAP Sensor Circuit High Voltage....6991
Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage....6994
Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage....6997
Diagnostic Trouble Code (DTC) P0117 ECT Sensor Circuit Low Voltage....7000
Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage....7003
Diagnostic Trouble Code (DTC) P0121 TP System Performance....7006
Diagnostic Trouble Code (DTC) P0122 TP Sensor Circuit Low Voltage....7009
Diagnostic Trouble Code (DTC) P0123 TP Sensor Circuit High Voltage....7012
Diagnostic Trouble Code (DTC) P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1....7015
Diagnostic Trouble Code (DTC) P0132 HO2S Circuit High Voltage Bank 1 Sensor 1....7018
Diagnostic Trouble Code (DTC) P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1....7021
Diagnostic Trouble Code (DTC) P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1....7024
Diagnostic Trouble Code (DTC) P0152 HO2S Circuit HIGH Voltage Bank 2 Sensor 1....7027
Diagnostic Trouble Code (DTC) P0171 Fuel Trim System Lean Bank 1....7030
Diagnostic Trouble Code (DTC) P0172 Fuel Trim System Rich Bank 1....7034
Diagnostic Trouble Code (DTC) P0174 Fuel Trim System Lean Bank 2....7038
Diagnostic Trouble Code (DTC) P0175 Fuel Trim System Rich Bank 2....7042
Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit....7046
Diagnostic Trouble Code (DTC) P0202 Injector 2 Control Circuit....7049
Diagnostic Trouble Code (DTC) P0203 Injector 3 Control Circuit....7052
Diagnostic Trouble Code (DTC) P0204 Injector 4 Control Circuit....7055
Diagnostic Trouble Code (DTC) P0205 Injector 5 Control Circuit....7058
Diagnostic Trouble Code (DTC) P0206 Injector 6 Control Circuit....7061
Diagnostic Trouble Code (DTC) P0325 KS Module Circuit....7064
Diagnostic Trouble Code (DTC) P0327 KS Sensor Circuit....7066
Diagnostic Trouble Code (DTC) P0336 58X Reference Signal Circuit....7069
Diagnostic Trouble Code (DTC) P0337 CKP Sensor Circuit Low Frequency....7071
Diagnostic Trouble Code (DTC) P0341 CMP Sensor Circuit Performance....7074
Diagnostic Trouble Code (DTC) P0342 CMP Sensor Circuit Low....7078
Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit....7082
Diagnostic Trouble Code (DTC) P0352 Ignition 2 Control Circuit....7085
Diagnostic Trouble Code (DTC) P0353 Ignition 3 Control Circuit....7088
Diagnostic Trouble Code (DTC) P0354 Ignition 4 Control Circuit....7091
Diagnostic Trouble Code (DTC) P0355 Ignition 5 Control Circuit....7094
Diagnostic Trouble Code (DTC) P0356 Ignition 6 Control Circuit....7097
Diagnostic Trouble Code (DTC) P0402 EGR Pintle Crank Error....7100
Diagnostic Trouble Code (DTC) P0404 EGR Open Stuck....7102
Diagnostic Trouble Code (DTC) P0405 EGR Low Voltage....7104
Diagnostic Trouble Code (DTC) P0406 EGR High Voltage....7107
Diagnostic Trouble Code (DTC) P0502 VSS Circuit Low Input....7110
Diagnostic Trouble Code (DTC) P0562 System Voltage Low....7113
Diagnostic Trouble Code (DTC) P0563 System Voltage High....7115
Diagnostic Trouble Code (DTC) P0601 PCM Memory....7116
Diagnostic Trouble Code (DTC) P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1....7117
Diagnostic Trouble Code (DTC) P1171 Fuel System Lean During Acceleration....7121
Diagnostic Trouble Code (DTC) P1380 ABS Rough Road ABS System Fault....7124
Diagnostic Trouble Code (DTC) P1404 EGR Closed Stuck....7125
Diagnostic Trouble Code (DTC) P1508 IAC System Low RPM....7127
Diagnostic Trouble Code (DTC) P1509 IAC System High RPM....7130
Diagnostic Trouble Code (DTC) P1618 Serial Peripheral Interface (SPI) PCM Interprocessor Communication Error....7133
Diagnostic Trouble Code (DTC) P1625 PCM Unexpected Reset....7134
Diagnostic Trouble Code (DTC) P1640 Driver-1-Input High Voltage....7135
Symptom Diagnosis....7138
Default Matrix Table....7164
Camshaft Position (CMP) Sensor....7167
Crankshaft Position (CKP) Sensor....7168
Engine Coolant Temperature (ECT) Sensor....7168
Heated Oxygen Sensor (HO2S)....7169
Intake Air Temperature (IAT) Sensor....7171
Knock Sensor (KS)....7172
Mass Air Flow (MAF) Sensor....7173
Manifold Absolute Pressure (MAP) Sensor....7173
Malfunction Indicator Lamp (MIL)....7174
Powertrain Control Module (PCM)....7174
EEPROM....7176
Power Steering Pressure (PSP) Switch....7176
Throttle Position (TP) Sensor....7177
Vehicle Speed Sensor (VSS)....7178
Air Cleaner/Air Filter....7179
Idle Air Control (IAC) Valve....7180
Common Chamber....7181
Accelerator Cable Assembly....7181
Accelerator Pedal Replacement....7184
Fuel Filter Cap....7186
Fuel Filter....7186
Fuel Gauge Unit....7189
Fuel Injectors....7190
Fuel Pressure Regulator....7191
Fuel Metering System....7193
Fuel Pump Assembly....7194
Fuel Pump Relay....7195
Fuel Rail Assembly....7195
Fuel Tank....7197
Throttle Body (TB)....7199
Electronic Ignition System....7200
Catalytic Converter....7201
Air Conditioning Relay....7201
EVAP Canister Hoses....7202
EVAP Canister....7202
EVAP Canister Purge Solenoid....7203
Fuel Tank Vent Valve....7204
Linear Exhaust Gas Recirculation (EGR) Valve....7204
Positive Crankcase Ventilation (PCV) Valve....7205
Wiring and Connectors....7206
PCM Connectors and Terminals....7206
Wire Harness Repair: Twisted Shielded Cable....7206
Twisted Leads....7207
Weather-Pack Connector....7208
Com-Pack III....7209
Metri-Pack....7209
General Description....7211
General Description (PCM and Sensors)....7211
58X Reference PCM Input....7211
A/C Request Signal....7211
Crankshaft Position (CKP) Sensor....7211
Camshaft Position (CMP) Sensor and Signal....7211
Engine Coolant Temperature (ECT) Sensor....7211
Electrically Erasable Programmable Read Only Memory (EEPROM)....7212
Fuel Control Heated Oxygen Sensors....7212
Intake Air Temperature (IAT) Sensor....7212
Knock Sensor....7213
Linear Exhaust Gas Recirculation (EGR) Control....7213
Mass Air Flow (MAF) Sensor....7213
Manifold Absolute Pressure (MAP) Sensor....7214
Powertrain Control Module (PCM)....7214
PCM Function....7214
PCM Components....7215
PCM Voltage Description....7215
PCM Input/Outputs....7215
PCM Service Precautions....7215
Reprogramming The PCM....7215
Throttle Position (TP) Sensor....7215
Transmission Fluid Temperature (TFT) Sensor....7216
Transmission Range Switch....7216
Vehicle Speed Sensor (VSS)....7216
Use of Circuit Testing Tools....7216
Aftermarket Electrical and Vacuum Equipment....7216
Electrostatic Discharge Damage....7217
Upshift Lamp....7217
General Description (Air Induction)....7217
Air Induction System....7217
General Description (Fuel Metering)....7217
Acceleration Mode....7217
Accelerator Controls....7217
Battery Voltage Correction Mode....7217
CMP Signal....7217
Clear Flood Mode....7218
Deceleration Mode....7218
Engine Speed/Vehicle Speed/Fuel Disable Mode....7218
Fuel Cutoff Mode....7218
Fuel Injector....7218
Fuel Metering System Components....7218
Fuel Metering System Purpose....7218
Fuel Pressure Regulator....7219
Fuel Pump Electrical Circuit....7219
Fuel Rail....7219
Idle Air Control (IAC) Valve....7219
Run Mode....7220
Starting Mode....7220
Throttle Body Unit....7220
General Description (Electronic Ignition System)....7220
Camshaft Position (CMP) Sensor....7220
Crankshaft Position (CKP) Sensor....7221
Electronic Ignition....7221
Ignition Coils....7221
Ignition Control....7221
Ignition Control PCM Output....7223
Knock Sensor (KS) PCM Input....7223
Powertrain Control Module (PCM)....7223
Spark Plug....7223
A/C Clutch Diagnosis....7225
A/C Clutch Circuit Operation....7225
A/C Clutch Circuit Purpose....7225
A/C Request Signal....7225
General Description (Exhaust Gas Recirculation (EGR) System)....7225
EGR Purpose....7225
Linear EGR Valve....7225
Linear EGR Control....7225
Linear EGR Valve Operation and Results of Incorrect Operation....7225
EGR Pintle Position Sensor....7226
General Description (Positive Crankcase Ventilation (PCV) System)....7226
Crankcase Ventilation System Purpose....7226
Crankcase Ventilation System Operation....7226
6F ENGINE EXHAUST....7231
Service Precaution....7231
General Description....7232
Front Exhaust Pipe....7234
Front Exhaust Pipe and Associated Parts....7234
Removal....7234
Installation....7234
Three Way Catalytic Converter....7235
Removal....7235
Installation....7235
Exhaust Silencer....7236
Exhaust Silencer and Associated Parts....7236
Removal....7236
Installation....7236
Rear Exhaust pipe....7237
Rear Exhaust pipe and Associated Parts....7237
Removal....7237
Installation....7237
Main Data and Specifications....7238
6G ENGINE LUBRICATION....7239
Service Precaution....7239
General Description....7240
Oil Pump....7241
Oil Pump and Associated Parts....7241
Inspection and Repair....7242
Reassembly....7243
Oil Pan and Crankcase....7245
Removal....7245
Installation....7245
Oil Pump....7248
Removal....7248
Installation....7248
Oil Pump Oil Seal....7250
Removal....7250
Installation....7250
Oil Filter....7251
Removal....7251
Installation....7251
Main Data and Specification....7252
Special Tool....7253
6H ENGINE SPEED CONTROL SYSTEM....7254
Service Precaution....7254
Accelerator Pedal Control Cable....7255
Removal....7255
Inspection....7255
Installation....7255
Adjustment....7255
Accelerator Pedal....7256
Accelerator Pedal and Associated Parts....7256
Removal....7256
Installation....7256
Adjustment....7256
6J INDUCTION....7258
Service Precaution....7258
Air Cleaner Element....7259
Removal....7259
Inspection....7259
Installation....7259
Sec.6 ENGINE(4JG2)....7260
00 SERVICE INFORMATION....7260
TROUBLESHOOTING....7261
MAIN DATA AND SPECIFICATIONS....7279
SERVICE STANDARD....7282
SERVICING....7286
FIXING TORQUE....7297
SPECIAL TOOLS....7306
6A ENGINE MECHANICAL....7310
CYLINDER HEAD....7311
VALVE SPRING, VALVE STEM OIL SEAL, VALVE, VALVE GUIDE, PUSH ROD....7316
CAMSHAFT, TAPPET....7323
ROCKER ARM ASSEMBLY....7328
OIL PUMP....7330
CRANKSHAFT....7334
PISTON AND CONNECTING ROD....7343
CYLINDER BLOCK....7351
6A2 4JG2-NA/4JG2-TURBO ENGINE....7362
GENERAL DESCRIPTION....7362
ENGINE MOUNT (RH)....7364
ENGINE MOUNT (LH)....7365
INTERCOOLER (4JG2-T only)....7366
CYLINDER HEAD COVER....7367
INLET MANIFOLD....7369
EXHAUST MANIFOLD....7371
TURBOCHARGER (4JG2-T only)....7372
TIMING GEAR....7376
VALVE STEM OIL SEAL & VALVE SPRING....7382
ROCKER ARM SHAFT ASSEMBLY....7385
CYLINDER HEAD....7387
CRANKCASE....7392
OIL COOLER....7395
OIL PUMP ASSEMBLY....7397
PISTON, PISTON RING AND CONNECTING ROD....7398
CRANKSHAFT AND MAIN BEARING....7400
FRONT OIL SEAL....7406
REAR OIL SEAL....7407
ENGINE ASSEMBLY....7409
6B ENGINE COOLING....7414
GENERAL DESCRIPTION....7414
ON-VEHICLE SERVICE....7418
WATER PUMP....7418
THERMOSTAT....7420
RADIATOR....7422
6C FUEL SYSTEM....7426
GENERAL DESCRIPTION....7426
ON-VEHICLE SERVICE....7432
FUEL FILTER ASSEMBLY....7432
FUEL FILTER CARTRIGE....7433
INJECTION NOZZLE....7434
INJECTION PUMP ASSEMBLY....7439
FUEL TANK....7443
FUEL GAUGE UNIT....7444
FUEL FILLER CAP....7445
ACCELERATOR CONTROL....7446
ACCELERATOR CONTROL CABLE....7446
ACCELERATOR PEDAL....7448
AIR CLEANER....7449
6D ENGINE ELECTRICAL....7450
6D1 BATTERY....7450
GENERAL DESCRIPTION....7450
DIAGNOSIS....7450
ON-VEHICLE SERVICE....7452
BATTERY CHARGING....7452
JUMP STARTING....7452
REMOVAL AND INSTALLATION OF THE BATTERY....7453
6D2 STARTING SYSTEM....7454
GENERAL DESCRIPTION....7454
ON-VEHICLE SERVICE....7456
UNIT REPAIR....7458
6D3 CHARGING SYSTEM....7466
GENERAL DESCRIPTION....7466
DIAGNOSIS....7469
UNIT REPAIR....7470
6D6 QOSIII PREHEATING SYSTEM....7478
GENERAL DESCRIPTION....7478
SYSTEM DIAGRAM....7479
6F ENGINE EXHAUST....7484
GENERAL DESCRIPTION....7485
HANGERS....7485
GASKET....7485
ON-VEHICLE SERVICE....7486
FRONT EXHAUST PIPE....7486
CENTER EXHAUST PIPE....7488
EXHAUST SILENCER....7490
REAR EXHAUST PIPE....7492
Sec.6 ENGINE(4JX1)....7493
6A ENGINE MECHANICAL....7493
GENERAL DESCRIPTION....7494
SERVICE INFORMATION....7495
SERVICE STANDARD....7498
SERVICING....7501
SPECIAL TOOLS....7515
ENGINE ASSEMBLY....7518
ENGINE MOUNT (RH)....7520
ENGINE MOUNT (LH)....7521
INTERCOOLER....7522
CYLINDER HEAD COVER....7523
INTAKE MANIFOLD....7525
EXHAUST MANIFOLD....7526
TURBOCHARGER....7527
CYLINDER HEAD....7529
CYLINDER HEAD GASKET....7531
CAMSHAFT....7535
TIMING GEAR....7540
VALVE STEM SEAL, VALVE SPRING AND ADJUSTER....7548
VALVE CLEARANCE ADJUSTMENT....7555
OIL RAIL AND INJECTOR....7557
CRANK CASE....7560
CRANKSHAFT....7562
PISTON AND CONNECTING ROD....7572
CYLINDER BLOCK....7580
OIL PUMP ASSEMBLY....7586
OIL FILTER CARTRIDGE....7587
OIL COOLER....7587
6B ENGINE COOLING....7589
GENERAL DESCRIPTION....7590
ON-VEHICLE SERVICE....7594
WATER PUMP....7594
THERMOSTAT....7595
RADIATOR....7597
DRIVE BELT ADJUSTMENT....7599
6C ENGINE FUEL....7601
GENERAL DESCRIPTION....7601
ON-VEHICLE SERVICE....7608
FUEL FILTER ASSEMBLY....7608
FUEL FILTER CARTRIDGE....7608
INJECTOR....7610
HIGH PRESSURE OIL PUMP....7614
FUEL TANK....7620
FUEL GAUGE UNIT....7621
FUEL FILLER CAP....7621
6D ENGINE ELECTRICAL....7623
BATTERY....7623
GENERAL DESCRIPTION....7623
DIAGNOSIS....7623
ON-VEHICLE SERVICE....7625
MAIN DATA AND SPECIFICATIONS....7626
STARTING SYTEM....7627
GENERAL DESCRIPTION....7627
ON-VEHICLE SERVICE....7629
STARTER....7629
UNIT REPAIR....7630
CHARGING SYSTEM....7637
GENERAL DESCRIPTION....7637
DIAGNOSIS....7638
UNIT REPAIR....7639
MAIN DATA AND SPECIFICATIONS....7644
QOS4 PREHEATING SYSTEM....7645
GENERAL DESCRIPTION....7645
SYSTEM DIAGRAM....7645
INSPECTION ON QOS4 SYSTEM OPERATION....7646
6E ENGINE DRIVEABILITY AND EMISSIONS....7649
Specification....7655
Tightening Specifications....7655
Diagrams and Schematics....7656
ECM Wiring Diagram (1 of 6)....7656
ECM Wiring Diagram (2 of 6)....7657
ECM Wiring Diagram (3 of 6)....7658
ECM Wiring Diagram (4 of 6)....7659
ECM Wiring Diagram (5 of 6)....7660
ECM Wiring Diagram (6 of 6)....7661
ECM Pinouts....7662
ECM Pinout Table, 32-Way Connector ‐ J1 RED ‐ Upper....7662
ECM Pinout Table, 32-Way Connector ‐ J1 RED ‐ Lower....7663
ECM Pinout Table, 32-Way Connector ‐ J2 BLUE ‐ Upper....7664
ECM Pinout Table, 32-Way Connector ‐ J2 BLUE ‐ Lower....7665
ECM Pinout Table, 5-Way Connector ‐ J3....7666
Component Locator....7667
Sensors and Miscellaneous Component Locators....7669
Abbreviations Charts....7671
Diagnosis....7672
Strategy-Based Diagnostics....7672
DTC Stored....7672
No DTC....7672
No Matching Symptom....7672
Intermittents....7672
No Trouble Found....7672
Verifying Vehicle Repair....7672
General Service Information....7673
Serviceability Issues....7673
Visual/Physical Engine Compartment Inspection....7673
Basic Knowledge of Tools Required....7673
Serial Data Communications....7673
Class II Serial Data Communications....7673
On-Board Diagnostic (OBD)....7673
On-Board Diagnostic Tests....7673
Comprehensive Component Monitor Diagnostic Operation....7673
Common OBD Terms....7674
The Diagnostic Executive....7674
DTC Types....7674
Verifying Vehicle Repair....7675
Reading Flash Diagnostic Trouble Codes....7675
Reading Diagnostic Trouble Codes Using a TECH 2....7676
Tech 2 Scan Tool....7677
Getting Started....7678
DTC Modes....7680
DTC Information Mode....7680
Injector Test....7680
EGR Valve Test....7680
Rail Pressure Control Valve Test....7680
Injector Balance Test....7680
Data Programming in Case of ECM Change....7680
Rail Pressure Sensor Programming....7681
Injector Group Sign Programming (Injector Change)....7681
On-Board Diagnostic (OBD) System Check....7683
Circuit Description....7685
Diagnostic Aids....7685
Engine Control Module ECM Diagnosis....7687
Multiple ECM Information Sensor DTCS Set....7687
Circuit Description....7687
Diagnostic Aids....7687
EGR (Exhaust Gas Recirculation) Diagnosis....7689
Tech 2 Data Definitions and Ranges....7689
Typical Scan Data Values....7689
Test Conditions....7689
4JX1-TC Engine (Automatic and Manual Transmission)....7690
No Malfunction Indicator Lamp (MIL)....7692
Circuit Description....7692
Diagnostic Aids....7692
Malfunction Indicator Lamp (MIL) “ON” Steady....7695
Circuit description....7695
Diagnostic Aids....7695
Engine Cranks But Will Not Run....7697
Circuit Description....7697
Diagnostic Aids....7697
Exhaust Gas Recirculation (EGR) System Check....7700
Circuit Description....7700
ECM Diagnostic Trouble Codes....7702
ECM Diagnostic Trouble Codes....7702
DTC P0107 (Flash DTC 34) MAP Sensor Circuit Low Voltage....7704
Circuit Description....7704
Action Taken When the DTC Sets....7704
Conditions for Clearing the MIL/DTC....7704
Diagnostic Aids....7704
DTC P0108 (Flash DTC 34) MAP Sensor Circuit High Voltage....7706
Circuit Description....7706
Action Taken When the DTC Sets....7706
Conditions for Clearing the MIL/DTC....7706
Diagnostic Aids....7706
DTC P0112 (Flash DTC 23) IAT Sensor Circuit Low Voltage....7708
Circuit Description....7708
Action Taken When the DTC Sets....7708
Conditions for Clearing the MIL/DTC....7708
Diagnostic Aids....7708
Test Description....7709
Intake Air Temperature Sensor....7709
DTC P0113 (Flash DTC 23) IAT Sensor Circuit High Voltage....7710
Circuit Description....7710
Action Taken When the DTC Sets....7710
Conditions for Clearing the MIL/DTC....7710
Diagnostic Aids....7710
Test Description....7711
Manifold Air Temperature Sensor....7711
DTC P0117 (Flash DTC 14) ECT Sensor Low Voltage....7713
Circuit Description....7713
Action Taken When the DTC Sets....7713
Conditions for Clearing the MIL/DTC....7713
Diagnostic Aids....7713
Test Description....7713
Engine Coolant Temperature Sensor....7714
DTC P0118 (Flash DTC 14) ECT Sensor High Voltage....7715
Circuit Description....7715
Action Taken When the DTC Sets....7715
Conditions for Clearing the MIL/DTC....7715
Diagnostic Aids....7715
Test Description....7716
Engine Coolant Temperature Sensor....7716
DTC P0121 (Flash DTC 33) AP Sensor Rationality....7718
Circuit Description....7718
Action Taken When the DTC Sets....7718
Conditions for Clearing the MIL/DTC....7718
Diagnostic Aids....7718
DTC P0122 (Flash DTC 21) AP Sensor Low Voltage....7720
Circuit Description....7720
Action Taken When the DTC Sets....7720
Conditions for Clearing the MIL/DTC....7720
Diagnostic Aids....7720
DTC P0123 (Flash DTC 21) AP Sensor High Voltage....7723
Circuit Description....7723
Action Taken When the DTC Sets....7723
Conditions for Clearing the MIL/DTC....7723
Diagnostic Aids....7723
Test Description....7723
DTC P0182 (Flash DTC 15) FT Sensor Low Voltage....7726
Circuit Description....7726
Action Taken When the DTC Sets....7726
Conditions for Clearing the MIL/DTC....7726
Diagnostic Aids....7726
Test Description....7726
DTC P0183 (Flash DTC 15) FT Sensor High Voltage....7728
Circuit Description....7728
Action Taken When the DTC Sets....7728
Conditions for Clearing the MIL/DTC....7728
Diagnostic Aids....7728
Test Description....7728
DTC P0192 (Flash DTC 63) Rail Pressure Sensor Low Voltage....7730
Circuit Description....7730
Action Taken When the DTC Sets....7730
Conditions for Clearing the MIL/DTC....7730
Diagnostic Aids....7730
DTC P0193 (Flash DTC 63) Rail Pressure Sensor High Voltage....7732
Circuit Description....7732
Action Taken When the DTC Sets....7732
Conditions for Clearing the MIL/DTC....7732
Diagnostic Aids....7732
DTC P1193 (Flash DTC 64) RPCV Circuit Open/Short....7734
Circuit Description....7734
Action Taken When the DTC Sets....7734
Conditions for Clearing the MIL/DTC....7734
Diagnostic Aids....7734
DTC P1194 (Flash DTC 61) Rail Pressure System Low Voltage....7736
Circuit Description....7736
Action Taken When the DTC Sets....7736
Conditions for Clearing the MIL/DTC....7736
Diagnostic Aids....7736
DTC P1195 (Flash DTC 61) Rail Pressure System High Voltage....7738
Circuit Description....7738
Action Taken When the DTC Sets....7738
Conditions for Clearing the MIL/DTC....7738
Diagnostic Aids....7738
DTC P1196 (Flash DTC 62) Rail Pressure System High Warning....7740
Circuit Description....7741
Action Taken When the DTC Sets....7741
Conditions for Clearing the MIL/DTC....7741
Diagnostic Aids....7741
Test Description....7741
DTC P0197 (Flash DTC 16) Oil Temp Sensor Low Voltage....7742
Circuit Description....7742
Action Taken When the DTC Sets....7742
Conditions for Clearing the MIL/DTC....7742
Diagnostic Aids....7742
Test Description....7743
Engine Oil Temperature Sensor....7743
DTC P0198 (Flash DTC 16) Oil Temp Sensor High Voltage....7744
Circuit Description....7744
Action Taken When the DTC Sets....7744
Conditions for Clearing the MIL/DTC....7744
Diagnostic Aids....7744
Test Description....7745
Engine Oil Temperature Sensor....7745
DTC P0201 (Flash DTC 51) Injector # 1 Circuit Fault....7747
Circuit Description....7747
Action Taken When the DTC Sets....7747
Conditions for Clearing the MIL/DTC....7747
Diagnostic Aids....7747
Test Description....7747
Injector Test....7747
DTC P0202 (Flash DTC 52) Injector # 2 Circuit Fault....7749
Circuit Description....7749
Action Taken When the DTC Sets....7749
Conditions for Clearing the MIL/DTC....7749
Diagnostic Aids....7749
Test Description....7749
Injector Test....7749
DTC P0203 (Flash DTC 52) Injector # 3 Circuit Fault....7751
Circuit Description....7751
Action Taken When the DTC Sets....7751
Conditions for Clearing the MIL/DTC....7751
Diagnostic Aids....7751
Test Description....7751
Injector Test....7751
DTC P0204 (Flash DTC 54) Injector # 4 Circuit Fault....7753
Circuit Description....7753
Action Taken When the DTC Sets....7753
Conditions for Clearing the MIL/DTC....7753
Diagnostic Aids....7753
Test Description....7753
Injector Test....7753
DTC P0217 (Flash DTC 22) High Coolant Temp Waring....7755
Circuit Description....7755
Action Taken When the DTC Sets....7755
Conditions for Clearing the MIL/DTC....7755
Diagnostic Aids....7755
Test Description....7755
DTC P1217 (Flash DTC 36) High Oil Temp Warning....7757
Circuit Description....7757
Action Taken When the DTC Sets....7757
Conditions for Clearing the MIL/DTC....7757
Diagnostic Aids....7757
DTC P0219 (Flash DTC 11) Engine Over Speed Warning....7759
Circuit Description....7759
Action Taken When the DTC Sets....7759
Conditions for Clearing the MIL/DTC....7759
Diagnostic Aids....7759
DTC P0336 (Flash DTC 43) CKP (Crank Position) Sensor Out of Synchro....7762
Circuit Description....7762
Action Taken When the DTC Sets....7762
Conditions for Clearing the MIL/DTC....7762
Diagnostic Aids....7762
DTC P0337 (Flash DTC 43) CKP (Crank Position) Sensor No Signal....7764
Circuit Description....7764
Action Taken When the DTC Sets....7764
Conditions for Clearing the MIL/DTC....7764
Diagnostic Aids....7764
DTC P0341 (Flash DTC 41) CMP (Cam Position) Sensor Out of Synchro....7767
Circuit Description....7767
Action Taken When the DTC Sets....7767
Conditions for Clearing the MIL/DTC....7767
Diagnostic Aids....7767
Test Description....7767
DTC P0342 (Flash DTC 41) CMP (Cam Position) Sensor No Signal....7770
Circuit Description....7770
Action Taken When the DTC Sets....7770
Conditions for Clearing the MIL/DTC....7770
Diagnostic Aids....7770
Test Description....7770
DTC P0380 (Flash DTC 66) Glow Relay Circuit Open/Short....7774
Circuit Description....7774
Action Taken When the DTC Sets....7774
Conditions for Clearing the MIL/DTC....7774
Diagnostic Aids....7774
DTC P0381 (Flash DTC 67) Glow Lamp Circuit Open/Short....7776
Circuit Description....7776
Action Taken When the DTC Sets....7776
Conditions for Clearing the MIL/DTC....7776
Diagnostic Aids....7776
DTC P1403 (Flash DTC 32) EGR EVRV Fault....7778
Circuit Description....7778
Diagnostic Aids....7778
Test Description....7778
DTC P1404 (Flash DTC 31) EGR VSV Circuit....7780
Circuit Description....7780
Diagnostic Aids....7780
DTC P0405 (Flash DTC 26) EGR Pressure Sensor Low Voltage....7782
Action Taken When the DTC Sets....7782
Conditions for Clearing the MIL/DTC....7782
Diagnostic Aids....7782
DTC P1405 (Flash DTC 37) EGR EVRV Circuit Open/Short....7784
Circuit Description....7784
Action Taken When the DTC Sets....7784
Conditions for Clearing the MIL/DTC....7784
Diagnostic Aids....7784
DTC P0406 (Flash DTC 26) EGR Pressure Sensor High Voltage....7786
Action Taken When the DTC Sets....7786
Conditions for Clearing the MIL/DTC....7786
Diagnostic Aids....7786
DTC P0475 (Flash DTC 71) EXH #1 VSV Circuit....7788
Circuit Description....7788
Action Taken When the DTC Sets....7788
Conditions for Clearing the MIL/DTC....7788
Diagnostic Aids....7788
DTC P1475 (Flash DTC 71) EXH #2 VSV Circuit Open/Short....7790
Circuit Description....7790
Action Taken When the DTC Sets....7790
Conditions for Clearing the MIL/DTC....7790
Diagnostic Aids....7790
DTC P1485 (Flash DTC 74) ITP (Intake Thorottle Position) Sensor Low Voltage....7792
Circuit Description....7792
Action Taken When the DTC Sets....7792
Conditions for Clearing the MIL/DTC....7792
Diagnostic Aids....7792
DTC P1486 (Flash DTC 74) ITP (Intake Throttle Position) Sensor High Voltage....7794
Circuit Description....7794
Action Taken When the DTC Sets....7794
Conditions for Clearing the MIL/DTC....7794
Diagnostic Aids....7794
DTC P1487 (Flash DTC 73) Intake Throttle System Circuit Open/Start....7796
Circuit Description....7796
Action Taken When the DTC Sets....7796
Conditions for Clearing the MIL/DTC....7796
Diagnostic Aids....7796
DTC P1488 (Flash DTC 72) Intake Throttle Motor Control Circuit Signal Gap....7798
Circuit Description....7798
Action Taken When the DTC Sets....7798
Conditions for Clearing the MIL/DTC....7798
Diagnostic Aids....7798
DTC P0502 (Flash DTC 24) VSS (Vehicle Speed Sensor) No Signal....7800
Circuit Description....7800
Action Taken When the DTC Sets....7800
Conditions for Clearing the MIL/DTC....7800
Test Description....7801
DTC P0510 (Flash DTC 75) Idle SW Malfunction, Open Circuit....7803
Circuit Description....7803
Action Taken When the DTC Sets....7803
Conditions for Clearing the MIL/DTC....7803
Diagnostic Aids....7803
DTC P1510 (Flash DTC 75) Idle SW Malfunction Short Circuit....7805
Circuit Description....7805
Action Taken When the DTC Sets....7805
Conditions for Clearing the MIL/DTC....7805
Diagnostic Aids....7805
DTC P0562 (Flash DTC 35) System Voltage Too Low....7807
Circuit Description....7807
Action Taken When the DTC Sets....7807
Conditions for Clearing the MIL/DTC....7807
Diagnostic Aids....7807
DTC P1562 (Flash DTC 35) System Voltage Too Low at Cranking....7808
Circuit Description....7808
Action Taken When the DTC Sets....7808
Conditions for Clearing the MIL/DTC....7808
Diagnostic Aids....7808
DTC P1587 (Flash DTC 25) Brake SW Malfunction....7809
Circuit Description....7809
Action Taken When the DTC Sets....7809
Conditions for Clearing the MIL/DTC....7809
Diagnostic Aids....7809
DTC P1588 (Flash DTC 25) Brake SW Malfunction....7811
Circuit Description....7811
Action Taken When the DTC Sets....7811
Conditions for Clearing the MIL/DTC....7811
Diagnostic Aids....7811
DTC P0601 (Flash DTC 55) ECM Checksum Error....7813
Action Taken When the DTC Sets....7813
Conditions for Clearing the MIL/DTC....7813
Diagnostic Aids....7813
DTC P0650 (Flash DTC 77) Check Engine Lamp Circuit Open/Short....7814
Circuit Description....7814
Action Taken When the DTC Sets....7814
Conditions for Clearing the MIL/DTC....7814
Diagnostic Aids....7814
DTC P0654 (Flash DTC 27) Tachometer Circuit Open/Short....7816
Circuit Description....7816
Action Taken When the DTC Sets....7816
Conditions for Clearing the MIL/DTC....7816
Diagnostic Aids....7816
DTC P1655 (Flash DTC 17) Thermo Relay Circuit Open/Short....7818
Circuit Description....7818
Action Taken When the DTC Sets....7818
Conditions for Clearing the MIL/DTC....7818
Diagnostic Aids....7818
DTC P1657 (Flash DTC 76) ECM Main Relay Circuit Open/Short....7820
Circuit Description....7820
Action Taken When the DTC Sets....7820
Conditions for Clearing the MIL/DTC....7820
Diagnostic Aids....7820
DTC P1589 (Flash DTC 47) Transmission SW Circuit Open/Short....7822
Circuit Description....7822
Action Taken When the DTC Sets....7822
Conditions for Clearing the MIL/DTC....7822
Diagnostic Aids....7822
Symptom Diagnosis....7824
Default Matrix Table....7847
On‐Vehicle Service Camshaft Position (CMP) Sensor....7849
Removal Procedure....7849
Inspection Procedure....7849
Installation Procedure....7849
Crankshaft Position (CKP) Sensor....7850
Removal Procedure....7850
Installation Procedure....7850
Engine Coolant Temperature (ECT) Sensor....7851
Removal Procedure....7851
Installation Procedure....7851
Intake Air Temperature (IAT) Sensor....7851
Removal Procedure....7851
Installation Procedure....7852
Manifold Absolute Pressure (MAP) Sensor....7852
Removal Procedure....7852
Installation Procedure....7853
Oil Temperature (OT) Sensor....7853
Removal Procedure....7853
Installation Procedure....7854
Malfunction Indicator Lamp (MIL)....7854
Removal and Installation Procedure....7854
Engine Control Module (ECM)....7854
Service Precaution....7854
Electrostatic Discharge (ESD) Damage....7854
Removal Procedure....7855
Installation Procedure....7856
EEPROM....7856
General Description....7856
Functional Check....7856
Intake Throttle Position (ITP) Sensor....7856
Removal Procedure....7856
Function Check....7857
Installation Procedure....7857
Vehicle Speed Sensor (VSS)....7858
Removal Procedure....7858
Inspection Procedure....7858
Installation Procedure....7858
Air Cleaner/Air Filter....7859
Removal Procedure....7859
Installation Procedure....7859
Accel Position (AP) Sensor....7859
Removal Procedure....7859
Installation Procedure....7860
Accelerator Pedal Replacement....7860
Removal Procedure....7860
Installation Procedure....7860
Fuel Filter Cap....7861
General Description....7861
Inspection Procedure....7861
Fuel Filter....7861
Removal and Installation Procedure....7861
Fuel Gauge Unit....7861
Removal Procedure....7861
Installation Procedure....7862
Fuel Injectors....7862
Removal and Installation Procedure....7862
Fuel Temperature Sensor....7862
Removal Procedure....7862
Installation Procedure....7863
Rail Pressure (RP) Sensor....7864
Removal Procedure....7864
Installation Procedure....7864
Fuel Tank....7864
Removal Procedure....7864
Throttle Body (TB)....7865
Removal Procedure....7865
Installation Procedure....7865
Air Conditioning (A/C) Relay....7865
Removal Procedure....7865
Installation Procedure....7865
Exhaust Gas Recirculation (EGR) Vacuum Switch Valve (VSV)....7865
Removal Procedure....7865
Installation Procedure....7866
Electronic Vacuum Regurating Valve (EVRV)....7867
Removal Procedure....7867
Installation Procedure....7868
Wiring and Connectors....7868
Wiring Harness Service....7868
Connectors and Terminals....7868
Wire Harness Repair: Twisted Shielded Cable....7868
Removal Procedure....7868
Installation Procedure....7869
Twisted Leads....7869
Removal Procedure....7869
Installation Procedure....7870
Weather-Pack Connector....7871
Tools Required....7871
Removal Procedure....7871
Installation Procedure....7871
Com-Pack III....7872
General Information....7872
Metri-Pack....7872
Tools Required....7872
Removal Procedure....7872
Installation Procedure....7872
General Description (ECM and Sensors)....7873
57X Reference ECM Input....7873
A/C Request Signal....7873
Crankshaft Position (CKP) Sensor....7873
Camshaft Position (CMP) Sensor and Signal....7873
Engine Coolant Temperature (ECT) Sensor....7873
Electrically Erasable Programmable Read Only Memory (EEPROM)....7873
Intake Air Temperature (IAT) Sensor....7873
Manifold Absolute Pressure (MAP) Sensor....7874
Engine Control Module (ECM)....7874
ECM Function....7874
ECM Components....7874
ECM Voltage Description....7874
ECM Input/Outputs....7874
ECM Service Precautions....7875
Intake Throttle Position (ITP) Sensor....7875
Transmission Range Switch....7875
Accelerator Position Sensor (AP)....7875
Aftermarket Electrical and Vacuum Equipment....7875
Electrostatic Discharge Damage....7875
General Description (Air Induction)....7876
Air Induction System....7876
General Description (Fuel Metering)....7876
Deceleration Mode....7876
Fuel Injector....7876
Fuel Metering System Components....7876
A/C Clutch Diagnosis....7876
A/C Request Signal....7876
General Description Exhaust Gas Recirculation (EGR) System....7876
EGR Purpose....7876
Fuse and Relay Panel (Underhood Electrical Center) RHD....7877
Fuse and Relay Panel (Underhood Electrical Center) LHD....7878
6F ENGINE EXHAUST....7879
GENERAL DESCRIPTION....7880
HANGERS....7880
GASKET....7880
ON-VEHICLE SERVICE....7881
FRONT EXHAUST PIPE....7881
CENTER EXHAUST PIPE....7883
EXHAUST SILENCER....7884
REAR EXHAUST PIPE....7885
6G ENGINE LUBRICATION....7887
GENERAL DESCRIPTION....7888
LUBRICATION CHART....7888
OIL FLOW....7889
OIL PUMP SPECIFICATIONS....7889
OIL FILTER SPECIFICATIONS....7889
SUB OIL FILTER SPECIFICATIONS....7890
OIL PUMP....7891
OIL COOLER ASSEMBLY....7892
OIL COOLER SPECIFICATIONS....7892
OIL FILTER....7892
SUB OIL FILTER....7892
6H ENGINE SPEED CONTROL....7893
GENERAL DESCRIPTION....7894
ENGINE SPEED CONTROL....7895
6J INDUCTION....7897
GENERAL DESCRIPTION....7898
AIR CLEANER....7899
TURBOCHARGER....7900
INTERCOOLER....7904
INTAKE THROTTLE VALVE....7905
INTAKE MANIFOLD....7906
MAIN DATA AND SPECIFICATIONS....7907
Sec.7 TRANSMISSION....7909
7A AUTOMATIC TRANSMISSION (4L30‐E)....7909
Service Precaution....7911
Construction....7911
Range Reference Chart....7912
Normal Operation Of 2000 4L30‐E Transmission....7913
Diagnosis....7913
Driver Information....7913
General Diagnosis Procedure....7916
Preliminary Inspection Chart....7917
Checking Transmission Fluid Level and Condition....7918
Test Driving....7919
Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart....7920
Mechanical / Hydraulic Diagnosis Symptoms Index....7921
Stall Test....7931
Line Pressure Test....7931
Shift Speed Chart (V6 3.2L 6VD1 Model)....7932
Shift Speed Chart (V6 3.5L 6VE1 Model)....7934
Lockup Speed Chart (V6 3.2L 6VD1 Model)....7936
Lockup Speed Chart (V6 3.5L 6VE1 Model)....7936
Changing Transmission Fluid....7937
Selector Lever....7937
Inspection....7937
Removal....7938
Installation....7938
Mode Switch....7939
Removal....7939
Installation....7939
Transmission (With Transfer Case)....7941
Transmission And Associated Parts....7941
Removal....7941
Installation....7943
Solenoid (Main Case Valve Body)....7947
Removal....7947
Installation....7947
Solenoid (Adapter Case Valve Body)....7948
Removal....7948
Installation....7948
Valve Body Assembly (Main Case)....7949
Removal....7949
Installation....7949
Valve Body Assembly (Adapter Case)....7951
Removal....7951
Installation....7951
Powertrain Control Module (PCM)....7951
Removal....7951
Installation....7951
Speed Sensor (Extension Housing)....7952
Removal....7952
Installation....7952
Transmission Oil Temperature Sensor (Adapter Case)....7952
Removal....7952
Installation....7953
Front Oil Seal (Converter Housing)....7953
Removal....7953
Installation....7953
Rear Oil Seal (Extension Housing)....7954
Removal....7954
Installation....7954
Transmission (4L30‐E)....7954
Disassembly....7954
Reassembly....7958
Converter Housing And Oil Pump Assembly....7968
Disassembled View....7968
Disassembly....7968
Inspection And Repair....7968
Reassembly....7968
Oil Pump....7969
Disassembled View....7969
Disassembly....7969
Inspection And Repair....7969
Reassembly....7969
Main Case Valve Body....7970
Disassembled View....7970
Disassembly....7970
Inspection And Repair....7971
Reassembly....7971
Adapter Case Valve Body....7972
Disassembled View....7972
Disassembly....7972
Inspection And Repair....7972
Reassembly....7972
Third Clutch And Sprag Unit....7973
Disassembled View....7973
Disassembly....7973
Inspection And Repair....7974
Reassembly....7974
Third Clutch....7975
Disassembled View....7975
Disassemble....7975
Inspection And Repair....7975
Reassembly....7975
Sprag Unit....7977
Disassembled View....7977
Disassembly....7977
Inspection And Repair....7977
Reassembly....7977
Second Clutch....7978
Disassembled View....7978
Disassembly....7978
Inspection And Repair....7979
Reassembly....7979
3–4 Accumulator Piston....7980
Disassembled View....7980
Disassembly....7980
Inspection And Repair....7981
Reassembly....7981
Reverse Clutch Piston And Center Support....7982
Disassembled View....7982
Disassembly....7983
Inspection And Repair....7983
Reassembly....7983
Overrun Clutch And Turbine Shaft....7984
Disassembled View....7984
Disassembly....7985
Inspection And Repair....7985
Reassembly....7985
Main Data And Specification....7987
Special Tools....7991
4L30–E Parts List....7994
7A AUTOMATIC TRANSMISSION (AW30-40LE)....8001
GENERAL DESCRIPTION....8003
CONSTRUCTION....8003
ELECTRONIC CONTROL COMPONENTS....8004
TRANSMISSION CONTROL MODULE (TCM)....8005
CONTROL SYSTEM DIAGRAM....8006
CONTROL AND FUNCTIONS....8007
MAJOR INPUT/OUTPUT COMPONENTS....8009
LOCATION OF CLUTCH, BRAKE, ONE-WAY CLUTCH AND SOLENOID....8010
OPERATION OF CLUTCH, BRAKE AND ONE-WAY CLUTCH....8011
SPEED CHANGE AND LOCK-UP PATTERN....8011
OVERDRIVE AND LOCK-UP OPERATING CONDITIONS....8012
DIAGNOSIS....8013
BASIC TROUBLESHOOTING....8013
SELF-DIAGNOSIS....8014
DIAGNOSIS WITH TECH2....8017
TECH2 CONNECTION....8018
TECH2 OPERATING FLOW CHART (START UP)....8019
TRANSMISSION DATA....8021
TCC DATA....8022
INTERMITTENT CONDITIONS....8023
IDENTIFICATION OF TRANSMISSION CONTROL MODULE (TCM)....8024
DIAGNOSTIC TROUBLE CODES (DTC) CHECK....8025
WIRING DIAGRAM....8052
CONNECTOR LIST....8054
TROUBLESHOOTING CHART....8056
MANUAL SHIFTING TEST....8062
STALL TEST....8063
TIME LAG TEST....8064
HYDRAULIC TEST....8065
ROAD TEST....8066
SHIFT POINT CHART AND LOCK-UP POINT CHART....8069
TCM VOLTAGE CHECK....8071
TCM STANDARD VOLTAGE....8072
ON-VEHICLE SERVICE....8075
TRANSIMISSION FLUID LEVEL AND CONDITION....8075
ATF REPLACEMENT....8075
NEUTRAL START SWITCH INSPECTION....8076
BRAKE SIGNAL INSPECTION....8077
VEHICLE SPEED SENSOR INSPECTION....8077
INPUT AND OUTPUT REVOLUTION SENSOR INSPECTION....8077
PATTERN SELECT SWITCH INSPECTION....8078
OVERDRIVE OFF SWITCH INSPECTION....8078
SOLENOID INSPECTION....8078
THROTTLE POSITION SENSOR INSPECTION....8079
ATF TEMPERATURE SENSOR INSPECTION....8079
SELECTOR LEVER....8080
TRANSMISSION CONTROL MODULE (TCM)....8083
SHIFT SOLENOID AND LOCK-UP SOLENOID....8083
VALVE BODY ASSEMBLY AND PRESSERE CONTOROL SOLENOID....8084
TRANSMISSION REMOVAL AND INSTALLATION....8086
UNIT REPAIR....8091
DISASSEMBLY OF MAJOR COMPONENTS....8091
DISASSEMBLY, INSPECTION AND REASSEMBLY OF MINOR COMPONENTS....8107
OIL PUMP....8108
OD PLANETARY GEAR AND OD DIRECT CLUTCH ASSEMBLY (C-0)....8114
OD SUPPORT ASSEMBLY....8126
DIRECT CLUTCH ASSEMBLY (C-2)....8133
FORWARD CLUTCH ASSEMBLY (C-1)....8141
FRONT PLANETARY GEAR....8150
PLANETARY SUN GEAR AND NO.1 ONE–WAY CLUTCH....8153
SECOND BRAKE ASSEMBLY (B–2)....8158
REAR PLANETARY GEAR ASSEMBLY AND OUTPUT SHAFT....8163
FIRST AND REVERSE BRAKE (B–3)....8171
TRANSMISSION CASE....8177
TORQUE CONVERTER....8181
REASSEMBLY OF MAJOR COMPONENTS....8182
MAIN DATA AND SPECIFICATIONS....8207
GENERAL SPECIFICATIONS....8207
TORQUE SPECIFICATIONS....8208
SPECIAL TOOLS....8211
7A1 TRANSMISSION CONTROL SYSTEM (4L30‐E)....8213
Service Precaution....8214
General Description....8214
Electronic Control Diagram....8215
Powertrain Control Module (PCM)....8216
Control System Diagram....8217
Shift Control....8218
Band Apply Control....8218
Torque Converter Clutch Control....8218
Line Pressure Control....8218
On–Board Diagnostic System....8218
Fail Safe Mechanism....8218
Torque Management Control....8218
ATF Warning Control....8218
ABS Control (If equipped)....8218
Shift Mode Control....8219
Gear Shift Control....8220
Winter Drive Mode....8221
Backup Mode....8221
Functions of Input / Output Components....8222
Diagnosis....8223
Electronic Diagnosis....8223
Check Trans Indicator....8223
Diagnostic Check....8223
“Check Trans” Check....8224
Tech2 OBD II Connection....8225
F0: Transmission Data....8230
F1: PC Solenoid Data....8231
OBD II Diagnostic Management System....8232
16 – Terminal Data Link Connector (DLC)....8233
Malfunction Indicator Lamp (MIL)....8234
Types Of Diagnostic Trouble Codes (DTCs)....8234
Clear DTC....8234
DTC Check....8235
PCM Precaution....8235
Information On PCM....8235
Intermittent Conditions....8235
Transmission And PCM Identification....8236
Isuzu Trooper....8237
Diagnostic Trouble Code (DTC) Identification....8238
DTC P0218 Transmission Fluid Over Temperature....8239
DTC P0560 System Voltage Malfunction....8241
DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position....8244
DTC P0706 Transmission Range Switch (Mode Switch) Performance....8247
DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input....8250
DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input....8253
DTC P0719 TCC Brake Switch Circuit High (Stuck On)....8256
DTC P0722 Transmission Output Speed Sensor (OSS) Low Input....8259
DTC P0723 Transmission Output Speed Sensor (OSS) Intermittent....8262
DTC P0730 Transmission Incorrect Gear Ratio....8265
DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical....8268
DTC P0753 Shift Solenoid A Electrical....8270
DTC P0758 Shift Solenoid B Electrical....8273
DTC P1790 ROM Transmission Side Bad Check Sum....8277
DTC P1792 EEPROM Transmission Side Bad Check Sum....8278
DTC P1835 Kickdown Switch Always On....8279
DTC P1850 Brake Band Apply Solenoid Malfunction....8281
DTC P1860 TCC Solenoid Electrical....8285
Transmission Fluid Temperature (TFT) Sensor Specifications....8288
7B MANUAL TRANSMISSION (AR-5)....8289
Service Precaution....8289
General Description....8290
Diagnosis....8292
Manual Transmission Assembly....8293
Transmission and Associated Parts....8293
Removal....8294
Installation....8299
Rear Oil Seal (Transfer Adapter)....8305
Removal....8305
Installation....8305
Transmission (AR-5)....8306
Disassembled View....8306
Disassembly....8309
Inspection....8327
Reassembly....8329
Main Data and Specifications....8356
General Specifications....8356
Torque Specifications....8357
Special Tools....8360
7B MANUAL TRANSMISSION (MUA)....8362
4X2 MODEL TRANSMISSION....8363
Main Data and Specifications....8363
General Description....8364
Torque Specifications....8365
Recommended Liquid Gasket....8367
Removal and Installation....8368
Disassembly....8377
Inspection and Repair....8387
Reassembly....8392
4X4 MODEL TRANSMISSION....8407
Main Data and Specifications....8407
General Description....8408
Torque Specifications....8409
Recommended Liquid Gasket....8411
Removal and Installation....8412
Disassembly....8422
Inspection and Repair....8442
Reassembly....8448
Troubleshooting....8473
7C CLUTCH....8481
Service Precaution....8481
General Description....8482
Diagnosis....8488
Clutch Assembly....8489
Clutch Assembly and Associated Parts....8489
Removal....8489
Inspection and Repair....8490
Installation....8495
Clutch Control....8497
Clutch Control Parts....8497
Removal....8498
Inspection and Repair....8498
Installation....8499
Adjustment....8499
Master Cylinder....8502
Disassembled View....8502
Disassembly....8503
Inspection and Repair....8503
Reassembly....8503
Slave Cylinder....8504
Disassembled View....8504
Disassembly....8504
Inspection and Repair....8504
Reassembly....8505
Damper Cylinder....8506
Disassembled View....8506
Disassembly....8506
Inspection and Repair....8506
Reassembly....8506
Main Data and Specifications....8507
General Specifications....8507
Torque Specifications....8507
Special Tools....8510
Sec.8 BODY AND ACCESSORIES....8511
8A LIGHTING SYSTEM....8511
Service Precaution....8512
Headlight Bulb....8513
Removal....8513
Installation....8513
Headlight....8514
Headlight and Associated Parts....8514
Removal....8514
Installation....8514
Headlight Adjustment....8514
Fog Light Bulb....8515
Removal....8515
Installation....8515
Fog Light Assembly....8516
Removal....8516
Installation....8516
Fog Light Adjustment....8516
Clarence Light Bulb....8516
Removal....8516
Installation....8516
Rear Fog Light Bulb (RHD)....8517
Removal....8517
Installation....8517
Taillight Bulb (Body)....8517
Removal....8517
Installation....8517
Taillight Bulb (Bumper)....8518
Removal....8518
Installation....8518
License Plate Light Bulb (Body)....8518
Removal....8518
Installation....8518
License Plate Light Bulb (Bumper)....8519
Removal....8519
Installation....8519
Stoplight Bulb....8519
Removal and Installation....8519
High Mount Stoplight....8520
Removal....8520
Installation....8520
Front Turn Signal Light Bulb....8520
Removal....8520
Installation....8520
Side Turn Signal Light Bulb....8521
Removal....8521
Installation....8521
Rear Turn Signal Light Bulb....8521
Removal....8521
Installation....8521
Backup Light Bulb....8522
Removal....8522
Installation....8522
Dome Light Bulb....8522
Removal....8522
Installation....8522
Luggage Room Light Bulb....8523
Removal....8523
Installation....8523
Courtesy Light Bulb....8523
Removal....8523
Installation....8523
Map Light Switch/Bulb....8524
Removal....8524
Installation....8524
Ashtray Illumination Bulb....8525
Removal....8525
Installation....8525
Glove Box Illumination Bulb....8525
Removal....8525
Installation....8525
Vanity Mirror Illumination Bulb....8526
Removal....8526
Installation....8526
Starter Switch....8527
Removal....8527
Installation....8527
Lighting Switch (Combination Switch)....8528
Removal....8528
Installation....8528
Fog Light Switch....8529
Removal....8529
Installation....8529
Stoplight Switch (W/O Cruise Control)....8530
Removal....8530
Installation....8530
Brake Switch (W/Cruise Control)....8531
Removal....8531
Installation....8531
Turn Signal Switch (Combination Switch)....8531
Removal and Installation....8531
Hazard Warning Switch....8532
Removal....8532
Installation....8532
Tailgate Switch....8533
Removal....8533
Installation....8533
Door Switch....8533
Removal....8533
Installation....8533
Rear Defogger Switch....8534
Removal....8534
Installation....8534
Seat Heater Switch....8535
Removal....8535
Installation....8535
Key Remind Switch (Starter Switch)....8535
Removal and Installation....8535
Illumination Controller....8536
Removal....8536
Installation....8536
Power/Winter Switch....8537
Removal....8537
Installation....8537
Main Data and Specifications....8538
8B WIPER / WASHER SYSTEM....8541
Service Precaution....8542
Windshield Wiper/Washer System....8542
General Description....8542
Windshield Wiper And Washer Switch....8542
Removal and Installation....8542
Windshield Wiper Motor....8542
Removal....8542
Installation....8542
Windshield Washer Motor....8543
Removal....8543
Installation....8543
Windshield Wiper Linkage....8544
Windshield Wiper Linkage and Associated Parts....8544
Removal....8544
Installation....8544
Windshield Wiper Arm/Blade....8545
Removal....8545
Installation....8545
Windshield Wiper Blade Rubber....8546
Removal....8546
Installation....8546
Rear Wiper/Washer System....8547
General Description....8547
Rear Wiper and Washer Switch....8547
Removal....8547
Installation....8547
Rear Wiper Motor....8548
Removal....8548
Installation....8548
Alarm & Relay Control Unit....8549
Removal....8549
Installation....8549
Rear Washer Motor....8549
Removal....8549
Installation....8549
Rear Wiper Arm/Blade....8550
Removal....8550
Installation....8550
Rear Washer Nozzle....8550
Removal....8550
Installation....8550
Rear Washer Nozzle Angle Adjustment....8550
Rear Wiper Blade Rubber....8551
Removal and Installation....8551
Headlight Wiper/Washer....8551
General Description....8551
Headlight Wiper and Washer Switch....8552
Removal....8552
Installation....8552
Headlight Wiper Arm & Blade....8553
Removal....8553
Installation....8553
Headlight Wiper Motor....8553
Removal....8553
Installation....8553
Headlight Washer Motor....8554
Removal and Installation....8554
Main Data and Specifications....8554
8C ENTERTAINMENT....8555
Service Precaution....8555
Cigarette Lighter....8556
General Description....8556
Removal....8556
Installation....8556
Digital Clock....8557
Removal....8557
Installation....8557
Rod Type Antenna....8558
Removal....8558
Installation....8558
Auto Antenna....8559
General Description....8559
Removal....8559
Installation....8559
Antenna Rod....8560
Removal....8560
Installation....8560
Radio....8561
Removal....8561
Installation....8561
Front Speaker....8562
Removal....8562
Installation....8562
Rear Speaker....8563
Removal....8563
Installation....8563
8D WIRING SYSTEM....8565
Service Precaution....8567
General Description....8568
Notes for Working on Electrical Items....8568
Symbols and Abbreviations....8574
Parts for Electrical Circuit....8576
Reading the Circuit Diagram....8585
Main Data and Specifications....8588
Fuse, Fusible Link and Circuit Breaker Location....8588
Relay Location....8591
Diode Location....8594
Grounding Point....8595
Cable Harness Routing....8607
Fuse Block Circuit....8615
Circuit Diagram....8616
Start and Charging....8629
General Description....8629
Circuit Diagram....8630
Parts Location....8632
Powertrain Control Module (PCM)....8642
General Description....8642
Circuit Diagram....8643
Parts Location....8655
QOS-III (4JG2)....8673
General Description....8673
Circuit Diagram....8674
Parts Location....8676
QOS and EGR System (4JG2)....8680
General Description....8680
Circuit Diagram....8681
Parts Location....8684
Headlight and Fog Light....8689
General Description....8689
Circuit Diagram....8690
Parts Location....8692
Diagnosis....8696
Rear Fog Light....8712
General Description....8712
Circuit Diagram....8713
Parts Location....8716
Diagnosis....8717
Headlight Leveling....8719
General Description....8719
Circuit Diagram....8720
Parts Location....8721
Diagnosis....8722
Clearance Light, Taillight and License Plate Light....8725
General Description....8725
Circuit Diagram....8726
Parts Location....8729
Diagnosis....8734
Interior Illumination Light....8746
General Description....8746
Circuit Diagram....8747
Parts Location....8751
Diagnosis....8758
Turn Signal Light and Hazard Warning Light....8759
General Description....8759
Circuit Diagram....8760
Parts Location....8763
Parts Location....8767
Stoplight....8774
General Description....8774
Circuit Diagram....8775
Parts Location....8778
DIAGNOSIS....8782
Backup Light....8786
General Description....8786
Circuit Diagram....8787
Parts Location....8789
Diagnosis....8793
Horn....8796
General Description....8796
Circuit Diagram....8797
Parts Location....8798
Diagnosis....8801
Dome Light, Luggage Room Light, Courtesy Light and Map Light....8803
General Description....8803
Circuit Diagram....8804
Parts Location....8806
Power Door Lock....8810
General Description....8810
Circuit Diagram....8811
Parts Location....8816
Diagnosis....8822
Power Window....8827
General Description....8827
Circuit Diagram....8828
Parts Location....8829
Diagnosis....8832
Cruise Control....8838
General Description....8838
Circuit Diagram....8839
Parts Location....8841
Diagnosis....8845
Anti-lock Brake System (ABS)....8850
General Description....8850
Circuit Diagram....8851
Parts Location....8857
A/T Shift Lock....8864
General Description....8864
Circuit Diagram....8865
Parts Location....8866
Windshield Wiper/Washer....8869
General Description....8869
Circuit Diagram....8870
Parts Location....8871
Diagnosis....8874
Rear Wiper/Washer....8882
General Description....8882
Circuit Diagram....8883
Parts Location....8885
Diagnosis....8889
Headlight Wiper/Washer....8895
General Description....8895
Circuit Diagram....8896
Parts Location....8898
Diagnosis....8902
Rear Defogger....8908
General Description....8908
Circuit Diagram....8909
Parts Location....8910
Diagnosis....8913
Audio....8916
General Description....8916
Circuit Diagram....8917
Parts Location....8921
Cigarette Lighter and Digital Clock....8925
General Description....8925
Circuit Diagram....8926
Parts Location....8927
Power Door Mirror....8930
General Description....8930
Circuit Diagram....8931
Parts Location....8934
Diagnosis....8939
Anti-Theft System with Keyless Entry....8946
Circuit Diagram....8947
Parts Location....8958
Diagnosis....8965
Meter and Warning/Indicator Light....8978
General Description....8978
Circuit Diagram....8979
Parts Location....8997
Diagnosis....9013
A/T Shift Indicator....9032
General Description....9032
Circuit Diagram....9033
Parts Location....9035
Heater and Air Conditioning....9039
General Description....9039
Circuit Diagram....9040
Parts Location....9042
Sun Roof....9052
General Description....9052
Circuit Diagram....9053
Parts Location....9054
Diagnosis....9057
Seat Heater....9061
General Description....9061
Circuit Diagram....9062
Parts Location....9063
Diagnosis....9066
Power Seat....9068
General Description....9068
Circuit Diagram....9069
Parts Location....9071
Diagnosis....9075
Shift On The Fly System....9081
Circuit Diagram....9082
Parts Location....9084
Torque on Demand (T.O.D.)....9106
Circuit Diagram....9107
Parts Location....9110
Supplemental Restraint System (SRS) – Air Bag....9111
General Description....9111
Circuit Diagram....9112
Parts Location....9116
Connector List....9118
8E METER AND GAUGE....9153
Service Precaution....9153
General Description....9153
Meter Assembly....9154
General Description....9154
Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination Lights....9154
Table for Meter/Gauge Connector Terminal Connections....9160
Removal....9168
Installation....9168
Warning Light Bulb, Indicator Light Bulb, Illumination Light Bulb, A/T Indicator Light Bulb....9168
Removal....9168
Installation....9168
Vehicle Speed Sensor....9169
Removal....9169
Installation....9169
Fuel Tank Unit....9169
Removal....9169
Installation....9169
Multi Meter....9170
Removal....9170
Installation....9170
Ambient Sensor....9170
Removal....9170
Installation....9170
Main Data and Specifications....9171
8F BODY STRUCTURE....9172
Service Precaution....9174
Frame....9174
General Description....9174
Frame Dimensions (L W B)....9175
Frame Dimensions (S W B)....9176
General Description....9177
Front Bumper....9177
Parts Location....9177
Removal....9178
Installation....9178
Front Bumper Slider Bracket....9178
Removal....9178
Installation....9178
Rear Bumper....9179
Parts Location....9179
Removal....9179
Installation....9180
Parts Location (W/Rear Combination Light and License Light)....9181
Removal....9181
Installation....9182
Rear Bumper Slider....9183
Removal....9183
Installation....9183
General Description....9184
Cowl Cover....9184
Parts Location....9184
Removal....9184
Installation....9185
Engine Hood....9185
Removal....9185
Installation....9185
Air Bulge....9186
Parts Location....9186
Removal....9186
Installation....9186
Engine Hood Hinge....9187
Parts Location....9187
Removal....9187
Installation....9187
Engine Hood Lock....9188
Parts Location....9188
Removal....9188
Installation....9189
Radiator Grille And Front End Lower Panel....9189
Parts Location....9189
Removal....9189
Installation....9190
Front Fender Panel....9191
Parts Location....9191
Removal....9191
Installation....9192
Body Mounting....9193
Parts Location....9193
Removal (No.1 – No. 2)....9193
Removal (No. 3 — No. 6)....9194
Installation....9195
General Description....9196
Body Dimension....9197
Instrument Panel Assembly....9217
Parts Location....9217
Removal....9218
Installation....9222
Cross Beam Assembly....9223
Parts Location....9223
Removal....9223
Installation....9224
Front Door Assembly....9225
Parts Location....9225
Removal....9225
Installation....9225
Rear Door Assembly....9226
Parts Location....9226
Removal....9226
Installation....9227
Door Strikers....9227
Adjustment....9227
Door Check Arm Assembly (Front & Rear)....9228
Parts Location....9228
Removal....9228
Installation....9229
Front Window Regulator, Glass And Glass Run....9229
Parts Location....9229
Removal....9229
Installation....9231
Rear Window Regulator And Glass....9232
Parts Location....9232
Removal....9232
Installation....9233
Rear Door Fixed Glass And Glass Run....9234
Parts Location....9234
Removal....9234
Installation....9235
Front Door Sash Moulding....9236
Parts Location....9236
Removal....9236
Installation....9236
Rear Door Moulding....9237
Parts Location....9237
Removal....9237
Installation....9237
Front Door Waist Seal....9238
Parts Location....9238
Removal....9238
Installation....9238
Rear Door Waist Seal....9239
Parts Location....9239
Removal and Installation....9239
Front Door Weatherstrip....9240
Parts Location....9240
Removal....9240
Installation....9241
Rear Door Weatherstrip....9242
Parts Location....9242
Removal and Installation....9242
Front Door Seal Finisher....9243
Parts Location....9243
Removal....9243
Installation....9243
Rear Door Seal Finisher....9244
Parts Location....9244
Removal....9244
Installation....9244
Tailgate Assembly (LH)....9245
Parts Location....9245
Removal....9245
Installation....9246
Tailgate Assembly (RH)....9247
Parts Location....9247
Removal....9247
Installation....9248
Tailgate Strikers....9249
Adjustment....9249
Tailgate Stopper Assembly....9249
Parts Location....9249
Removal....9249
Installation....9249
Tailgate Dove-Tail....9250
Parts Location....9250
Removal....9250
Installation....9250
Tailgate Dove-Tail Striker....9251
Adjustment....9251
Tailgate Frame Cover (LH)....9252
Parts Location....9252
Removal....9252
Installation....9252
Tailgate Frame Cover (RH)....9253
Removal....9253
Installation....9253
Tailgate Sash Trim Cover....9254
Parts Location....9254
Removal....9254
Installation....9254
Tailgate Outer Weatherstrip....9255
Parts Location....9255
Removal....9255
Installation....9255
Tailgate Center Weatherstrip....9256
Parts Location....9256
Removal....9256
Installation....9256
Tailgate Main Weatherstrip....9257
Parts Location....9257
Removal....9257
Installation....9257
Spare Tire Carrier....9258
Parts Location....9258
Removal....9258
Installation....9258
Headlining....9259
Parts Location....9259
Removal....9259
Installation....9260
Rear Air Deflector....9261
Parts Location....9261
Removal....9261
Installation....9261
Roof Moulding....9263
Parts Location....9263
Removal....9263
Installation....9264
Windshield....9265
Parts Location....9265
Removal....9265
Installation....9266
Rear Quarter Side Glass....9270
Parts Location....9270
Removal....9270
Installation....9271
Tailgate Glass....9273
Parts Location....9273
Removal....9273
Installation....9274
Main Data and Specifications....9275
Special Tools....9286
8G SEATS....9287
Service Precaution....9287
Front Seat Assembly....9288
Front Seat Assembly and Associated Parts....9288
Removal....9288
Installation....9289
Disassembled View (LWB)....9289
Disassembly....9290
Reassembly....9291
Disassembled View (SWB)....9292
Disassembly....9292
Reassembly....9294
Power Seat Assembly....9295
General Description....9295
Disassembled View....9295
Disassembly....9296
Reassembly....9298
Power Seat Switch....9298
Removal....9298
Installation....9298
Front Tilt Motor / Rear Tilt Motor / Slide Motor / Recliner Motor....9299
Parts Location....9299
Removal and Installation....9299
Seat Heater System....9300
General Description....9300
Seat Heater Switch Removal and Installation....9300
Heat Unit Parts Location....9300
Heat Unit Removal and Installation....9300
Rear Seat Assembly....9301
Rear Seat Assembly and Associated Parts....9301
Removal....9301
Installation....9301
Disassembled View (Split Type)....9302
Disassembly (Split Type)....9303
Reassembly (Split Type)....9304
Disassembled View (SWB)....9305
Disassembly....9305
Reassembly....9306
Disassembled View (Bench Type)....9307
Disassembly (Bench Type)....9308
Reassembly (Bench Type)....9309
Third Seat Assembly....9309
Parts Location....9309
Removal....9309
Installation....9310
Disassembled View....9310
Disassembly....9311
Reassembly....9311
Rear Seat Foot Rest....9311
Rear Seat Foot Rest and Associated Parts....9311
Removal....9312
Installation....9312
Main Data and Specifications....9312
8H SECURITY AND LOCKS....9314
Service Precaution....9315
Front Door Lock Assembly....9315
Front Door Lock Assembly and Associated Parts....9315
Removal....9315
Installation....9316
Front Outside Handle and Door Lock Cylinder....9317
Front Outside Handle, Door Lock Cylinder and Associated Parts....9317
Removal....9317
Installation....9318
Rear Door Lock Assembly....9320
Rear Door Lock Assembly and Associated Parts....9320
Removal....9320
Installation....9321
Rear Outside Handle....9322
Rear Outside Handle and Associated Parts....9322
Removal....9322
Installation....9323
Rear Door Inside Lock Knob Link....9323
Removal....9323
Installation....9323
Door Inside Lock Knob....9324
Removal....9324
Installation....9324
Door Inside Handle....9324
Removal and Installation....9324
Tailgate Lock Assembly (LH)....9325
Tailgate Lock Assembly (LH) and Associated Parts....9325
Removal....9325
Installation....9326
Tailgate Lock Assembly (RH)....9327
Tailgate Lock Assembly (RH) and Associated Parts....9327
Removal....9327
Installation....9328
Tailgate Inside Lock Knob....9328
Removal....9328
Installation....9328
Tailgate Inside Handle....9329
Parts Location....9329
Removal and Installation....9329
Tailgate Outside Handle and/or Tailgate Lock Cylinder....9330
Tailgate Outside Handle and/or Tailgate Lock Cylinder and Associated Parts....9330
Removal....9330
Installation....9331
Key....9332
Key Coding....9332
Key Styles....9332
Power Door Lock System....9333
General Description....9333
Front Door Lock Actuator Removal....9333
Front Door Lock Actuator Installation....9333
Rear Door Lock Actuator Removal....9333
Rear Door Lock Actuator Installation....9334
Tailgate Lock Actuator Removal....9334
Tailgate Lock Actuator Installation....9334
Anti-theft System....9335
General Description....9335
Anti-theft & Keyless Entry Control Unit Removal....9335
Anti-theft & Keyless Entry Control Unit Installation....9335
Anti-theft Indicator Removal....9335
Anti-theft Indicator Installation....9336
Anti-theft Horn Removal....9336
Anti-Theft Horn Installation....9336
Engine Hood Switch Removal....9336
Engine Hood Switch Installation....9336
Keyless Entry System....9337
ID Code Registration (Except South Africa)....9337
Anti‐theft & Keyless Entry Control Unit/Transmitter Replacement....9339
Programming With Tech 2 (For South Africa)....9340
Main Data and Specifications....9342
8I SUN ROOF/CONVERTIBLE TOP....9343
Service Precaution....9343
Sun Roof Glass....9344
Sun Roof Glass and Associated Parts....9344
Removal....9344
Installation....9345
Sun Roof Deflector....9346
Removal....9346
Installation....9346
Sunshade....9346
Disassembled View....9346
Removal....9347
Installation....9347
Sun Roof Frame Complete Assembly....9348
Sun Roof Frame Complete Assembly and Associated Parts....9348
Removal....9348
Installation....9349
Disassembled View....9349
Disassembly....9349
Reassembly....9350
Sun Roof Drain Hose (Front Side)....9351
Sun Roof Drain Hose (Front Side) and Associated Parts....9351
Removal....9351
Installation....9351
Sun Roof Drain Hose (Rear Side)....9352
Sun Roof Drain Hose (Rear Side) and Associated Parts....9352
Removal....9352
Installation....9352
Sun Roof Switch....9353
General Description....9353
Removal....9353
Installation....9353
Sun Roof Motor....9354
Removal....9354
Installation....9354
Main Data and Specifications....9354
8J EXTERIOR / INTERIOR TRIM....9355
Service Precaution....9356
Dash Side Trim Panel....9357
Removal....9357
Installation....9357
Assist Grip....9357
Parts Location....9357
Removal and Installation....9357
Consoles....9358
Consoles and Associated Parts....9358
Removal....9358
Installation....9359
Front Door Trim Panel....9360
Front Door Trim Panel and Associated Parts....9360
Removal....9360
Installation....9363
Rear Door Trim Panel....9364
Rear Door Trim Panel and Associated Parts....9364
Removal....9364
Installation....9365
Door Mirror....9367
Door Mirror and Associated Parts....9367
Removal....9367
Installation....9367
Luggage Side and Quarter Upper Trim Cover (LWB)....9368
Luggage Side, Quarter Upper Trim Cover and Associated Parts....9368
Removal....9368
Installation....9370
Luggage Side and Quarter Upper Trim Cover (SWB)....9371
Luggage Side, Quarter Upper Trim Cover and Associated Parts....9371
Removal....9371
Installation....9373
Center Pillar and Roof Side Trim Cover (LWB)....9374
Center Pillar, Roof Side Trim Cover and Associated Parts....9374
Removal....9374
Installation....9375
Roof Side Trim Cover (SWB)....9376
Roof Side Trim Cover and Associated Parts....9376
Removal....9376
Installation....9376
Front Pillar Trim Cover....9377
Front Pillar Trim Cover and Associated Parts....9377
Removal....9377
Installation....9377
Center Pillar Assist Grip....9378
Parts Location....9378
Removal and Installation....9378
Assist Grip....9378
Parts Location....9378
Removal and Installation....9378
Fuel Filler Lid Opener Cable....9379
Fuel Filler Lid Opener Cable and Associated Parts....9379
Removal....9379
Installation....9380
Fuel Filler Door....9380
Parts Location....9380
Removal....9380
Installation....9380
Rocker Protector (Without Wheel Opening Extension)....9381
Rocker Protector (Without Wheel Opening Extension) and Associated Parts....9381
Removal....9381
Installation....9381
Wheel Opening Extension and Rocker Protector Assembly....9382
Wheel Opening Extension, Rocker Protector Assembly and Associated Parts....9382
Removal....9382
Installation....9383
Mud Flaps (With Wheel Opening Extension)....9385
Mud Flaps (With Wheel Opening Extension) and Associated Parts....9385
Removal....9385
Installation....9385
Ventilation Assembly....9386
Ventilation Assembly and Associated Parts....9386
Removal....9386
Installation....9386
Quarter Flipper Glass Assembly (SWB)....9387
Quarter Flipper Glass Assembly and Associated Parts....9387
Removal....9387
Installation....9387
Tailgate Trim Panel (LH)....9388
Tailgate Trim Panel (LH) and Associated Parts....9388
Removal....9388
Installation....9389
Tailgate Trim Panel (RH)....9390
Parts Location....9390
Removal....9390
Installation....9390
Luggage Floor Box....9391
Luggage Floor Box and Associated Parts....9391
Remove....9391
Installation....9391
Rope Hook Set....9391
Rope Hook Set and Associated Parts....9391
Removal....9391
Installation....9391
Power Door Mirror System....9392
General Description....9392
Door Mirror Switch Assembly (Control Switch, Folding Switch and Defogger Switch) Removal....9392
Installation....9392
Power Door Mirror....9392
General Description....9392
Removal and Installation....9392
Power Window System....9393
General Description....9393
Power Window Switch Removal and Installation....9393
Power Window Motor Removal and Installation....9394
Main Data and Specifications....9395
Sec.9 RESTRAINTS....9396
9A SEAT BELT SYSTEM....9396
Service Precaution....9396
Seat Belt....9397
Front Seat Belt and Associated Parts (Long Wheel Base)....9397
Removal....9397
Inspection....9397
Installation....9398
Front Seat Belt and Associated Parts (Short Wheel Base)....9399
Removal....9399
Inspection....9399
Installation....9400
Rear Seat Belt and Associated Parts (Long Wheel Base)....9401
Removal....9401
Inspection....9401
Installation....9402
Rear Seat Belt and Associated Parts (Short Wheel Base)....9403
Removal....9403
Inspection....9404
Installation....9404
Third Seat Belt and Associated Parts (Long Wheel Base)....9405
Removal....9405
Inspection....9406
Installation....9406
Front Seat Buckle Assembly....9407
Removal....9407
Installation....9407
Front Seat Buckle Assembly (W/Pretensioner)....9407
Removal....9407
Installation....9407
Rear Center Seat Belt Buckle Assembly....9408
Rear Center Seat Belt Buckle Assembly and Associated Parts....9408
Removal....9408
Installation....9408
Third Seat Belt Buckle and Lock Assembly....9409
Third Seat Belt Buckle and Lock Assembly and Associated Parts....9409
Removal....9409
Installation....9409
Rear Seat Lock Assembly....9410
Removal....9410
Installation....9410
Rear Seat Lock Assembly (Bench Type)....9410
Removal....9410
Installation....9410
Rear Seat Strikers....9411
Removal....9411
Installation....9411
Third Seat Striker....9411
Removal....9411
Installation....9411
Main Data and Specifications....9412
9J SUPPLEMENTAL RESTRAINT SYSTEM....9413
Service Precaution....9413
General Description....9414
SRS Component And Wiring Location View....9416
Component Description....9416
Definitions....9419
Diagnosis....9420
SRS Connector Body Face Views....9421
Repairs And Inspections Required After An Accident....9421
On–Vehicle Service....9422
Air Bag Assembly Handling / Shipping / Scrapping....9423
Pretensioner Seat Belt Handling / Shipping / Scrapping.....9423
Special Tools....9438
Service Precautions for SRS Component Service....9442
SRS Connectors....9443
Sensing And Diagnostic Module (SDM)....9445
Service Precautions....9445
Removal....9445
Installation....9445
Driver Air Bag Assembly....9447
Service Precautions....9447
Removal....9447
Installation....9448
Steering Wheel....9449
Service Precautions....9449
Removal....9449
Installation....9450
SRS Coil Assembly....9451
Service Precautions....9451
Removal....9451
Installation....9453
SRS Coil Replacement Procedure....9454
Removal....9454
How to Disconnect the horn terminal....9455
How to Connect Horn Terminal....9455
Installation....9456
Steering Column....9456
Service Precautions....9456
Removal....9456
Installation....9458
Passenger Air Bag Assembly....9460
Service Precautions....9460
Removal....9460
Installation....9460
Pretensioner Seat Belt (If so equipped)....9461
Service Precaution....9461
Parts Location....9461
Removal....9461
Installation....9461
Main Data and Specifications....9462
9J1 RESTRAINT CONTROL SYSTEM....9463
Service Precaution....9463
Diagnostic Information....9464
System Schematic....9466
SRS Diagnostic System Check....9466
Chart A SDM Integrity Check....9468
Chart B “AIR BAG” Warning Lamp Comes “ON” Steady....9470
Chart C “AIR BAG” Warning Lamp Does Not Come “ON” Steady....9472
DTC 15 Passenger Deployment Loop Resistance High....9475
DTC 16 Passenger Deployment loop Resistance Low....9477
DTC 17 Passenger Deployment Loop Open....9479
DTC 18 Passenger Deployment Loop Short To Ground....9481
DTC 19 Passenger Deployment Loop Short To B+....9483
DTC 21 Driver Deployment Loop Resistance High....9485
DTC 22 Driver Deployment Loop Resistance Low....9488
DTC 24 Driver Deployment Loop Short To Ground....9491
DTC 25 Driver Deployment Loop Short To B+....9493
DTC 26 Driver Deployment Loop Open....9495
DTC 51 Air Bag Deployment Event Commanded....9497
DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy Reserves Out Of Range....9499
DTC 61 Warning Lamp Circuit Failure....9501
DTC 71 Internal SDM Fault....9503
DTC 29 Passenger Pretensioner Loop Short To Ground....9505
DTC 31 Passenger Pretensioner Loop Resistance High....9507
DTC 32 Passenger Pretensioner loop Resistance Low....9509
DTC 33 Passenger Pretensioner Loop Short To Voltage....9511
DTC 34 Passenger Pretensioner Loop Open....9513
DTC 41 Driver Pretensioner Loop Resistance High....9515
DTC 42 Driver Pretensioner Loop Resistance Low....9517
DTC 44 Driver Pretensioner Loop Open....9519
DTC 45 Driver Pretensioner Loop Short To Ground....9521
DTC 46 Driver Pretensioner Loop Short To Voltage....9523
DTC 52 Pretensioner Deployment Event Commanded....9525
Sec.10 CONTROL SYSTEM....9527
10A CRUISE CONTROL SYSTEM....9527
Service Precaution....9527
General Description....9527
Diagnosis....9528
Brake Switch....9528
Removal....9528
Installation....9528
Adjustment....9529
Clutch Switch....9529
Removal and Installation....9529
Adjustment....9529
Starter Switch....9530
Removal....9530
Installation....9530
Cruise Control Main Switch....9531
Removal....9531
Installation....9531
Cruise Control Switch (Combination Switch)....9531
Removal and Installation....9531
Cruise Control Unit....9532
Removal....9532
Installation....9532
Cruise Actuator....9533
Actuator Cable Diagram (LHD)....9533
Actuator Cable Diagram (RHD)....9533
Removal....9534
Installation....9534
Mode Switch....9534
Removal and Installation....9534
Sec.- IMMOBILIZER SYSTEM....9535
ISUZU UBS Immobilizer System Introduction....9537
What your organization should provide for customer....9537
System outline....9538
While the system is on....9538
What happens without proper transponder operation....9538
No proper transponder is available, what should be done for the system....9538
Caution to the operation....9539
Summary of operation....9539
Illustration of Instrument pannel....9539
Immobilizer system Gas Engine (6VE1 3.5L/6VD1 3.2L)....9540
Immobilizer system Diesel Engine (4JX1 3.0L)....9541
Immobilizer system Diesel Engine (4JG2 3.1L)....9542
Electrical Equipment - Instruments....9543
Location of Components....9543
Connector....9543
Electrical Equipment - Instruments....9544
Terminal Assignment of Wiring Harness Connector, Immobilizer Controller (6VE1,6VD1,4JX1)....9544
Terminal Assignment of Wiring Harness Connector, Immobilizer Controller (4JG2)....9545
Electrical Equipment - Instrument....9546
Function (Continued)....9546
Checking Component Requied....9547
Tech-II illustration....9547
Important information on Programing....9548
Security code....9548
1. Entering a code....9548
2. Getting started....9549
3. Transponder....9550
Transponder program....9550
Erase transponder key....9551
4. Reset Immobilizer ICU....9552
5. Reset Function....9553
6. Programing ICU, ECM....9555
Important....9559
Loss of car pass....9560
Diagnostic procedure....9562
1. 12V power is not supplied to ICU.....9563
2. Engine does not start after steering assembly is repaired.....9563
3. If engine does not start after ICU replacement, check part number.....9563
Immobilizer system Electrical wiring for Gas Engine (6VE1, 6VD1)....9569
2002 MODEL....0
UBS....9572
Sec.0 GENERAL INFORMATION....9585
0A GENERAL INFORMATION....9585
GENERAL REPAIR INSTRUCTIONS....9586
HOW TO USE THIS MANUAL....9587
IDENTIFICATION....9590
LIFTING INSTRUCTIONS....9592
TORQUE SPECIFICATIONS....9594
RECOMMENDED LIQUID GASKET....9595
RECOMMENDED THREAD LOCKING AGENTS....9595
ABBREVIATIONS CHARTS....9596
0B MAINTENANCE AND LUBRICATION....9598
MAINTENANCE SCHEDULE....9599
RECOMMENDED FLUIDS, LUBRICANTS AND FUELS....9604
OIL VISCOSITY CHART....9607
Sec.1 HEATING AND VENTILATION....9610
1A HEATING AND VENTILATION....9610
GENERAL DESCRIPTION....9611
HEATER....9611
CONTROL LEVER ASSEMBLY....9612
VENTILATION....9612
AIR SELECT KNOB....9613
AIR SOURCE SELECT LEVER....9613
FAN CONTROL KNOB....9613
TEMPERATURE CONTROL KNOB....9613
CERAMIC HEATER....9614
ON-VEHICLE SERVICE....9615
HEATER UNIT....9615
HEATER CORE AND/OR MODE DOOR....9617
HEATER MODE CONTROL LINK UNIT....9619
HEATER TEMPERATURE CONTROL LINK UNIT....9621
BLOWER ASSEMBLY....9623
BLOWER LINK UNIT AND/OR MODE DOOR....9625
BLOWER MOTOR....9627
REAR HEATER DUCT, DEFROSTER NOZZLE AND VENTILATION DUCT....9629
CENTER AND/OR SIDE VENT....9631
CONTROL LEVER ASSEMBLY AND/OR CONTROL CABLES....9633
CONTROL PANEL ILLUMINATION BULB....9636
RESISTOR....9637
CERAMIC HEATER AND/OR FULL HOT SWITCH....9639
1B AIR CONDITIONING....9642
GENERAL DESCRIPTION....9644
AIR CONDITIONING REFRIGERANT CYCLE CONSTRUCTION....9644
COMPRESSOR....9645
MAGNETIC CLUTCH....9646
RECEIVER/DRIER....9646
DUAL PRESSURE SWITCH....9647
TRIPLE PRESSURE SWITCH....9647
EXPANSION VALVE....9647
EVAPORATOR....9648
ELECTRONIC THERMOSTAT....9648
REFRIGERANT LINE....9648
SERVICE CHARGE VALVES....9648
AIR CONDITIONING PARTS....9649
ON-VEHICLE SERVICE....9654
PRECAUTIONS FOR REPLACEMENT OR REPAIR OF AIR CONDITIONING PARTS....9654
Compressor Assembly and Associated Parts....9664
CONDENSER ASSEMBLY (LHD V6 WITHOUT CONDENSER FAN)....9674
CONDENSER FAN MOTOR....9676
RECEIVER/DRIER....9678
PRESSURE SWITCH....9680
EVAPORATOR ASSEMBLY....9683
EVAPORATOR CORE AND/OR EXPANSION VALVE....9685
ELECTRONIC THERMOSTAT....9688
A/C SWITCH AND ILLUMINATION BULB....9689
REFRIGERANT LINE....9690
REAR COOLER PARTS....9692
FULL AUTOMATIC AIR CONDITIONING SYSTEM....9701
GENERAL DESCRIPTION....9701
Full Automatic Air Conditioner Parts Configuration....9701
CIRCUIT DIAGRAM....9703
FUNCTIONS AND FEATURES....9715
FULL AUTOMATIC AIR CONDITIONER BLOCK DIAGRAM....9716
AIR CONDITIONING PARTS....9717
Control Panel Layout....9721
Air Control Functions....9722
OPERATION AND FUNCTIONS OF CONTROL PANEL SWITCHES....9723
OVERVIEW OF CONSTRUCTION, MOVEMENT AND CONTROL OF MAJOR PARTS OF FULL AUTOMATIC AIR CONDITIONER SYSTEM....9725
OVERVIEW OF AUTOMATIC CONTROL OF FULL AUTOMATIC AIR CONDITIONER....9729
TROUBLESHOOTING....9733
Troubleshooting, Its Overview and Procedures....9733
Performance and Movement checklist for Automatic Air Conditioner Related Parts....9736
TROUBLESHOOTING WITH SELF-DIAGNOSIS FUNCTION....9738
INSPECTION BY FAILED LOCATION....9741
Inspection of the Sensors....9741
Inspection of the Intake Actuator System....9745
Inspection of the Mix Actuator System....9748
Inspection of the Mode Actuator System....9751
Inspection of the Fan Motor System....9754
Inspection of the Magnet Clutch System....9759
Inspection of the Air Conditioner Room Temperature Setup System....9764
INDIVIDUAL INSPECTION....9765
ON-VEHICLE SERVICE....9767
Power Transistor....9767
Automatic Heater/Air Conditioner Control Unit....9767
In Car Sensor....9768
Ambient Sensor....9768
Sun Sensor....9769
Electronic Thermostat....9769
Mode Actuator....9770
MIX Actuator....9770
Intake Actuator....9771
1D COMPRESSOR OVERHAUL....9772
GENERAL DESCRIPTION....9773
GENERAL INFORMATION....9775
COMPRESSOR OIL....9775
SERVICE PROCEDURE....9777
DKV-14D TYPE COMPRESSOR....9777
DKS-15CH TYPE COMPRESSOR....9781
HD6 TYPE COMPRESSOR....9789
Sec.2 SERVICE INFORMATION....9818
00 SERVICE INFORMATION....9798
TROUBLESHOOTING....9800
GENERAL INFORMATION....9801
GENERAL TROUBLESHOOTING....9801
POWER STEERING SYSTEM....9804
POWER STEERING PUMP....9805
STEERING COLUMN....9806
MAIN DATA AND SPECIFICATIONS....9808
SERVICE STANDARD....9809
SERVICING....9810
FIXING TORQUE....9812
SPECIAL TOOLS....9816
2A FRONT END ALIGNMENT....9818
GENERAL DESCRIPTION....9819
DEFINITION OF TERMS....9819
ON-VEHICLE SERVICE....9820
INSPECTION....9820
TRIM HEIGHT ADJUSTMENT....9820
CASTER ADJUSTMENT....9821
CAMBER ADJUSTMENT....9821
TOE-IN ADJUSTMENT....9822
MAXIMUM STEERING ANGLE ADJUSTMENT....9822
Sec.3 FRONT SUSPENSION....9904
3C FRONT SUSPENSION....9904
GENERAL DESCRIPTION....9905
ON-VEHICLE SERVICE....9906
SHOCK ABSORBER....9906
STABILIZER BAR....9908
TORSION BAR....9910
KNUCKLE....9913
UPPER CONTROL ARM....9917
LOWER CONTROL ARM....9921
UPPER BALL JOINT....9925
LOWER BALL JOINT....9928
3D REAR SUSPENSION; COIL SPRING....9931
GENERAL DESCRIPTION....9932
ON-VEHICLE SERVICE....9933
COIL SPRING....9933
SHOCK ABSORBER....9936
TRAILING LINK....9938
CENTER LINK....9940
LATERAL ROD....9942
STABILIZER BAR....9945
3E WHEELS AND TIRES....9947
GENERAL DESCRIPTION....9948
ON-VEHICLE SERVICE....9949
WHEELS....9949
UNIT REPAIR....9950
TIRES....9950
WHEELS....9951
GENERAL BALANCE PROCEDURE....9951
BALANCING WHEEL AND TIRE....9952
Sec.4 DRIVELINE/AXLE....9953
4A1 DIFFERENTIAL (FRONT)....9953
Service Precaution....9953
Front Drive Axle....9954
Diagnosis....9954
Pinion Shaft Oil Seal....9955
Pinion Shaft Oil Seal and Associated Parts....9955
Removal....9955
Inspection and Repair....9956
Installation....9956
Front Drive Axle Assembly....9957
Front Drive Axle Assembly and Associated Parts....9957
Removal....9957
Installation....9959
Differential Assembly....9961
Disassembled View....9961
Disassembly....9962
Reassembly....9964
Differential Cage Assembly....9973
Disassembled View....9973
Disassembly....9973
Inspection and Repair....9974
Reassembly....9975
Main Data and Specifications....9977
Special Tools....9980
4A2A DIFFERENTIAL (Rear 220mm)....9982
Service Precaution....9982
General Description....9983
Diagnosis....9984
Axle Housing....9985
Axle Housing and Associated Parts....9985
Removal....9985
Oil Seal Replacement....9986
Installation....9986
Axle Shaft....9987
Axle Shaft and Associated Parts....9987
Removal....9987
Inspection and Repair....9988
Oil Seal Replacement....9989
Installation....9989
Pinion Oil Seal....9990
Pinion Oil Seal and Associated Parts....9990
Removal....9990
Inspection and Repair....9991
Installation....9991
Differential Assembly....9992
Differential Assembly and Associated Parts....9992
Removal....9992
Installation....9993
Disassembled View....9994
Disassembly....9995
Reassembly....9997
Differential Cage Assembly....10005
Disassembled View....10005
Disassembly....10005
Inspection and Repair....10006
Reassembly....10007
Limited Slip Differential....10009
Disassembled View....10009
Disassembly....10010
Inspection and Repair....10010
Reassembly....10012
Main Data and Specifications....10016
Special Tools....10018
4A2B DIFFERENTIAL (REAR 244mm)....10020
Service Precaution....10020
General Description....10022
Diagnosis....10023
Axle Housing....10024
Axle Housing and Associated Parts....10024
Removal....10024
Oil Seal Replacement....10025
Installation....10025
Axle Shaft....10026
Axle Shaft and Associated Parts....10026
Removal....10026
Inspection and Repair....10027
Oil Seal Replacement....10028
Installation....10028
Pinion Oil Seal....10029
Pinion Oil Seal and Associated Parts....10029
Removal....10029
Inspection and Repair....10030
Installation....10030
Differential Assembly....10031
Differential Assembly and Associated Parts....10031
Removal....10031
Installation....10032
Disassembled View....10033
Disassembly....10034
Reassembly....10036
Differential Cage Assembly....10043
Disassembled View....10043
Disassembly....10044
Inspection and Repair....10044
Reassembly....10045
Limited Slip Differential....10047
Disassembled View....10047
Disassembly....10048
Inspection and Repair....10048
Reassembly....10050
Main Data and Specifications....10054
Special Tools....10056
4B1 DRIVELINE CONTROL SYSTEM (SHIFT ON THE FLY)....10058
Service Precaution....10058
Shift on the Fly System (Lever Type)....10059
Outline of Shift on the Fly System (Lever Type)....10059
Shift on the Fly Vacuum Piping and Electric Equipment (For Lever Control Type)....10060
Vacuum Piping Diagram....10060
Inspection and Repair....10061
Shift on the Fly System (Push Button Type)....10064
Outline of Shift on the Fly System (Push Button Type)....10064
Functions of Indicator Lamp....10068
Diagnosis....10068
Front Axle Diagnosis....10087
Shift on the Fly Vacuum Piping and Electric Equipment (For Push Button Type)....10089
Vacuum Piping Diagram....10089
Inspection and Repair....10090
4WD Control Unit (For Push Button Type)....10093
4WD Control Unit Associated Parts....10093
Removal....10094
Installation....10094
4B2 DRIVELINE CONTROL SYSTEM (TOD)....10096
Service Precaution....10096
General Description....10097
System Components....10099
Parts Location....10099
Functions of Indicator Lamp....10103
Diagnosis....10108
Basic Diagnostic Flow Chart....10112
Parts Location (RHD 6VE1)....10113
Circuit Diagram–1 (RHD 6VE1)....10117
Connector List....10129
Checking Failed Pin....10131
Checking Failed TOD Control Unit Pin....10134
Diagnostic Trouble Codes....10138
Diagnosis from Trouble Codes....10139
Trouble Diagnosis Depending on The Status of TOD Indicator....10169
Diagnosis from Symptom....10209
4C DRIVE SHAFT SYSTEM....10219
Service Precaution....10220
General Description....10220
Diagnosis....10221
Rear Axle Shaft....10222
Rear Axle Shaft and Associated Parts....10222
Removal....10222
Inspection and Repair....10223
Oil Seal Replacement....10224
Installation....10224
Special Tools....10226
Front Hub and Disc (with Shift on the Fly)....10227
Disassembled View....10227
Disassembly....10227
Inspection and Repair....10228
Reassembly....10229
Front Hub and Disc with Manual Locking Hub....10232
Disassembled View....10232
Disassembly....10232
Inspection and Repair....10234
Reassembly....10234
Main Data and Specifications....10238
Special Tools....10239
Front Drive Shaft Joint....10240
Front Drive Shaft Joints Replacement....10240
Front Axle Drive Shaft....10241
Front Axle Drive Shaft and Associated Parts....10241
Disassembly....10242
Inspection and Repair....10243
Bushing Replacement....10243
Reassembly....10244
Shift On The Fly System....10246
Shift On The Fly System and Associated Parts....10246
Disassembly....10246
Inspection and Repair....10248
Main Data and Specifications....10253
Special Tools....10254
Front Propeller Shaft....10255
General Description....10255
Front Propeller Shaft and Associated Parts....10256
Removal....10256
Installation....10257
Disassembly (Except TOD 4×4)....10258
Universal Joint Disassembly....10259
Inspection and Repair....10260
Universal Joint Reassembly....10263
Reassembly (Except TOD 4×4)....10264
Main Data and Specifications....10265
Rear Propeller Shaft....10266
General Description....10266
Rear Propeller Shaft and Associated Parts....10266
Removal....10267
Installation....10267
Disassembly....10268
Universal Joint Disassembly....10269
Inspection and Repair....10270
Universal Joint Reassembly....10271
Reassembly....10272
Main Data and Specifications....10273
4D1 TRANSFER CASE (STANDARD TYPE)....10274
Service Precaution....10274
General Description....10275
Transfer Rear Oil Seal....10281
Removal....10281
Installation....10281
Transfer Case Assembly....10282
Removal....10282
Installation....10283
Transfer Rear Cover Assembly (4WD Switch Model)....10284
Transfer Rear Cover Assembly and Associated Parts....10284
Removal....10285
Installation....10286
Disassembly....10289
Inspection and Repair....10290
Reassembly....10290
Transfer Rear Cover Assembly (Except 4WD Switch Model)....10292
Transfer Rear Cover Assembly and Associated Parts....10292
Removal....10293
Installation....10293
Disassembly....10296
Inspection and Repair....10297
Reassembly....10297
Detent, Shift Arm, and Interlock Pin....10299
Disassembled View....10299
Disassembly....10299
Inspection and Repair....10301
Reassembly....10301
Transfer Case Assembly....10303
Disassembled View....10303
Disassembly....10304
Inspection and Repair....10306
Reassembly....10310
Main Data and Specifications....10316
Special Tools....10319
4D2 TRANSFER CASE (TOD)....10320
Service Precaution....10320
Transfer Case Assembly....10321
Removal....10321
Installation....10322
Transfer Rear Oil Seal....10324
Transfer Rear Oil Seal and Associated Parts....10324
Removal....10324
Installation....10324
TOD ECU....10326
Removal....10326
Installation....10326
Unit Repair....10327
Inspection....10327
Transfer Case....10328
Disassembled View....10328
Disassembly....10328
Reassembly....10329
Transfer Cover Assembly....10331
Disassembled View....10331
Disassembly....10331
Reassembly....10333
Transfer Case Assembly Clutch Pack and Clutch Cam....10335
Disassembled View....10335
Disassembly....10335
Sprocket and Mechanical Lock....10337
Disassembled View....10337
Disassembly....10337
Output Shafts and Shift Control Shaft....10339
Disassembled View....10339
Disassembly....10340
Transfer Case....10342
Disassembled View....10342
Disassembly....10343
Inspection and Repair....10345
Transfer Case....10349
Disassembled View....10349
Reassembly....10349
Output Shafts and Shift Control Shaft....10353
Disassembled View....10353
Reassembly....10353
Sprocket and Mechanical Lock....10356
Disassembled View....10356
Reassembly....10356
Clutch Pack and Clutch Cam....10358
Disassembled View....10358
Reassembly....10358
Main Data and Specifications....10360
Special Tools....10362
Sec.5 BRAKES....10363
5A BRAKE CONTROL SYSTEM....10363
Service Precaution....10364
General Description....10365
System Components....10365
Electronic Hydraulic Control Unit (EHCU)....10365
ABS Warning Light....10366
Wheel Speed Sensor....10366
G-Sensor....10366
Normal and Anti-lock Braking....10366
Brake Pedal Travel....10366
Acronyms and Abbreviations....10366
General Diagnosis....10367
General Information....10367
ABS Service Precautions....10367
Computer System Service Precautions....10367
General Service Precautions....10367
Note on Intermittents....10367
Test Driving ABS Complaint Vehicles....10368
“ABS” Warning Light....10368
Normal Operation....10368
Basic Diagnostic Flow Chart....10368
Basic Inspection Procedure....10369
Tech 2 Scan Tool....10370
Getting Started....10371
Operating Procedure....10372
Data List....10373
EHCU Connector Pin-out Checks....10374
Circuit Diagram (LHD model / 6VD1 and 4JG2)....10375
Circuit Diagram (LHD model / 4JG2)....10376
Circuit Diagram (LHD model / 4JG2)....10377
Circuit Diagram (LHD model / 6VD1)....10378
Circuit Diagram (LHD model / 6VD1)....10379
Connector List (LHD model)....10380
Part Location (LHD model)....10382
Circuit Diagram (RHD model / 6VD1 and 4JG2)....10383
Circuit Diagram (RHD model / 4JG2)....10384
Circuit Diagram (RHD model / 4JG2)....10385
Circuit Diagram (RHD model / 6VD1)....10386
Circuit Diagram (RHD model / 6VD1)....10387
Circuit Diagram (RHD model / 6VE1 and 4JX1)....10388
Circuit Diagram (RHD model / 4JX1)....10389
Circuit Diagram (RHD model / 4JX1)....10390
Circuit Diagram (RHD model / 6VE1)....10391
Circuit Diagram (RHD model / 6VE1)....10392
Connector List (RHD model)....10393
Part Location (RHD model)....10396
Symptom Diagnosis....10397
Chart A–1 ABS Works Frequently But Vehicle Does Not Decelerate....10397
Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)....10398
Chart A-2 Uneven Braking Occurs While ABS Works....10398
Chart A-3, TA-3 The Wheels Are Locked....10398
Chart A-4 Brake Pedal Feed Is Abnormal....10399
Chart A-5, TA-5 Braking Sound (From EHCU) Is Heard While Not Braking....10400
Diagnostic Trouble Codes....10401
Diagnosis By “ABS” Warning Light Illumination Pattern....10402
Diagnostic Trouble Codes (DTCs)....10402
Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated.....10405
Chart B-2 EHCU Abnormality (DTC 14)....10405
Chart B-3 Power Voltage Drop (DTC 15)....10406
Chart B-4 CLASS-2 Communication Line Abnormality (DTC 16)....10406
Chart B-5 G-Sensor Circuit (DTC 21)....10407
Chart B-6 Abnormal Transmission Input (DTC 23)....10408
Chart B-7 Transfer Monitor (DTC 24)....10409
Chart B-8 EHCU Pump Motor And Motor Relay Circuit (DTC 32)....10409
Chart B-9 EHCU Pump Valve And Valve Relay Circuit (DTC 35)....10409
Chart B-10 FL Isolation Solenoid Valve Abnormality (DTC 41)....10410
Chart B-11 FL Dump Solenoid Valve Abnormality (DTC 42)....10410
Chart B-12 FR Isolation Solenoid Valve Abnormality (DTC 43)....10410
Chart B-13 FR Dump Solenoid Valve Abnormality (DTC 44)....10411
Chart B-14 Rear Isolation Solenoid Valve Abnormality (DTC 45)....10411
Chart B-15 Rear Dump Solenoid Valve Abnormality (DTC 46)....10411
Chart B-16 FL Speed Sensor Disconnection (DTC 51)....10412
Chart B-17 FR Speed Sensor Disconnection (DTC 52)....10412
Chart B-18 RL Speed Sensor Disconnection (DTC 53)....10413
Chart B-19 RR Speed Sensor Disconnection (DTC 54)....10413
Chart B-20 FL Speed Sensor Short Circuit (DTC 61)....10414
Chart B-21 FR Speed Sensor Short Circuit (DTC 62)....10415
Chart B-22 RL Speed Sensor Short Circuit (DTC 63)....10416
Chart B-23 RR Speed Sensor Short Circuit (DTC 64)....10417
Chart B-24 Sensor Signal Input Abnormality (DTC 65)....10418
Sensor Signal Abnormality Criteria using TECH 2....10418
Unit Inspection Procedure....10419
Chart C-1-1 FL Sensor Output Inspection Procedure....10419
Chart C-1-2 FR Sensor Output Inspection Procedure....10420
Chart C-1-3 RL Sensor Output Inspection Procedure....10420
Chart C-1-4 RR Sensor Output Inspection Procedure....10421
Chart TC-1 Sensor Output Inspection Procedure (Use TECH 2)....10421
Chart C-2 Transmission Input Inspection Procedure....10422
Chart TC-2 Transmission Input Inspection Procedure (Use TECH 2)....10423
Special Tools....10424
5B ANTI-LOCK BRAKE SYSTEM....10425
Service Precaution....10425
Electronic Hydraulic Control Unit....10426
Electronic Hydraulic Control Unit and Associated Parts....10426
Removal....10426
Installation....10426
G-Sensor....10427
Removal....10427
Inspection and Repair....10427
Installation....10427
Front Wheel Speed Sensor....10428
Front Wheel Speed Sensor and Associated Parts....10428
Removal....10428
Inspection and Repair....10429
Installation....10429
Rear Wheel Speed Sensor....10430
Rear Wheel Speed Sensor and Associated Parts....10430
Removal....10430
Inspection and Repair....10430
Installation....10430
5C POWER ASSISTED BRAKE SYSTEM....10431
SERVICE PRECAUTION....10432
BRAKE SYSTEM DIAGNOSIS....10433
TROUBLESHOOTING....10435
MAIN DATA AND SPECIFICATIONS....10437
SERVICE STANDARD....10438
SERVICING....10439
FIXING TORQUE....10448
SPECIAL TOOLS....10451
GENERAL DESCRIPTION....10452
MASTER CYLINDER....10452
VACUUM BOOSTER....10453
DISC BRAKES....10454
ON-VEHICLE SERVICE....10455
BRAKE HOSE REPLACEMENT....10455
BRAKE PIPE REPLACEMENT....10457
P & B VALVE....10458
P & B VALVE REPLACEMENT....10459
LOAD SENSING PROPORTIONING VALVE (LSPV)....10460
BRAKE PEDAL REPLACEMENT....10464
STOPLIGHT SWITCH REPLACEMENT....10466
FLUID RESERVOIR TANK....10468
MASATER CYLINDER ASSEMBLY....10469
VACUUM BOOSTER ASSEMBLY....10471
EXTERIOR COMPONENTS....10474
FRONT DISC BRAKE....10477
BRAKE PADS REPLACEMENT....10477
CALIPER REPLACEMENT....10480
REBUILDING THE CALIPER....10483
REAR DISC BRAKE....10486
BRAKE PADS REPLACEMENT....10486
CALIPER REPLACEMENT....10489
REBUILDING THE CALIPER....10492
UNIT REPAIR....10495
MASTER CYLINDER....10495
VACUUM BOOSTER....10497
5D PARKING BRAKES....10498
SERVICE PRECAUTION....10498
MAIN DATA AND SPECIFICATIONS....10499
SERVICE STANDARD....10499
SERVICING....10500
FIXING TORQUE....10502
GENERAL DESCRIPTION....10503
ON-VEHICLE SERVICE....10504
PARKING BRAKE LEVER REPLACEMENT....10504
PARKING BRAKE CABLE....10506
Sec.6 ENGINE(8bit)....10509
6A ENGINE MECHANICAL....10509
Service Precaution....10510
General Description....10511
Engine Diagnosis....10512
Cylinder Head Cover LH....10526
Removal....10526
Installation....10527
Cylinder Head Cover RH....10529
Removal....10529
Installation....10530
Common Chamber....10532
Removal....10532
Installation....10532
Exhaust Manifold LH....10534
Removal....10534
Installation....10534
Exhaust Manifold RH....10535
Removal....10535
Installation....10535
Crankshaft Pulley....10536
Removal....10536
Installation....10536
Timing Belt....10537
Removal....10537
Installation....10538
Camshaft....10541
Removal....10541
Installation....10541
Cylinder Head....10545
Removal....10545
Installation....10545
Valve Stem Oil Controller , Valve Spring and Valve Guide....10547
Removal....10547
Installation....10547
Piston, Piston Ring and Connecting Rod....10548
Removal....10548
Installation....10549
Crankshaft and Main Bearings....10550
Removal....10550
Installation....10551
Rear Oil Seal....10555
Removal....10555
Installation....10555
Engine Assembly....10556
Removal....10556
Installation....10556
Cylinder Head....10560
Cylinder Head and Associated Parts....10560
Disassembly....10560
Clean....10561
Inspection and Repair....10561
Reassembly....10561
Valve Spring, Oil Controller, Valve, Valve Guide....10564
Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts....10564
Disassembly....10564
Inspection and Repair....10565
Reassembly....10568
Valve Clearance Adjustments....10569
Camshaft....10571
Camshaft and Associated Parts....10571
Disassembly....10571
Inspection and Repair....10572
Reassembly....10574
Crankshaft....10577
Crankshaft and Associated Parts....10577
Disassembly....10577
Inspection and Repair....10578
Inspection and Repair....10579
Reassembly....10581
Piston and Connecting Rod....10585
Piston, Connecting Rod and Associate Parts....10585
Disassembly....10585
Inspection and Repair....10586
Reassembly....10590
Cylinder Block....10593
Cylinder Block and Associated Parts....10593
Disassembly....10593
Inspection and Repair....10594
Reassembly....10595
Main Data and Specification....10598
Special Tool....10604
6B ENGINE COOLING....10606
Service Precaution....10606
General Description....10607
Diagnosis....10610
Draining and Refilling Cooling System....10611
Water Pump....10612
Water Pump and Associated Parts....10612
Removal....10612
Inspection....10612
Installation....10612
Thermostat....10613
Thermostat and Associated Parts....10613
Removal....10613
Inspection....10613
Installation....10613
Radiator....10614
Radiator and Associated Parts....10614
Removal....10614
Inspection....10615
Installation....10616
Drive Belt and Cooling Fan....10617
Drive Belt and Associated Parts....10617
Inspection....10617
Installation....10617
Main Data and Specifications....10618
Special Tool....10619
6C ENGINE FUEL....10620
Service Precaution....10620
General Description....10621
Fuel Metering....10622
Fuel Filter....10623
Fuel Filter and Associated Parts....10623
Removal....10623
Inspection....10623
Installation....10624
Inspection....10624
In‐Tank Fuel Filter....10624
Fuel Pump Flow Test....10624
Fuel Pump....10625
Fuel Pump and Associated Parts....10625
Removal....10625
Installation....10625
Fuel Pump Relay....10626
General Description....10626
Fuel Tank....10626
Fuel Tank and Associated Parts....10626
Removal....10626
Installation....10627
Fuel Tube / Quick – Connect Fittings....10627
Precautions....10627
Cautions During Work....10627
Removal....10627
Reuse of Quick–Connector....10629
Assembling Advice....10629
Fuel Gauge Unit....10630
Fuel Gauge Unit and Associated Parts....10630
Removal....10630
Installation....10630
Fuel Filler Cap....10631
General Description....10631
Inspection....10631
Main Data and Specifications....10631
6D1 ENGINE ELECTRICAL....10632
Service Precaution....10632
Battery....10633
General Description....10633
Diagnosis....10633
Battery Charging....10634
Jump Starting....10634
Battery Removal....10635
Battery Installation....10635
Main Data and Specifications....10636
6D2 IGNITION SYSTEM....10638
Service Precaution....10638
General Description....10639
Diagnosis....10639
Ignition Coil....10640
Removal....10640
Inspection and Repair....10640
Installation....10640
Spark Plug....10641
Removal....10641
Inspection and Repair....10641
Installation....10641
Crankshaft Angle Sensor....10642
Removal....10642
Installation....10642
Main Data and Specifications....10643
6D3 STARTING AND CHARGING SYSTEM....10644
Service Precaution....10644
Starting System....10645
General Description....10645
Diagnosis....10647
Starter....10648
Removal....10648
Installation....10648
Disassembled View....10649
Disassembly....10650
Inspection and Repair....10652
Reassembly....10656
Main Data and Specifications....10658
Charging System....10661
General Description....10661
General On–Vehicle Inspection....10661
Generator....10662
Removal....10662
Inspection....10662
Installation....10662
Disassembled View....10663
Disassembly....10664
Inspection and Repair....10666
Reassembly....10667
Bench Test....10668
Main Data and Specifications....10669
6E ENGINE DRIVEABILITY AND EMISSIONS....10670
Specifications....10674
Tightening Specifications....10674
Vehicle Type Specifications....10674
Diagrams and Schematics....10675
PCM Wiring Diagram (1 of 11)....10675
PCM Wiring Diagram (2 of 11) For EC, THAILAND, SOUTH EAST ASIA, LATIN AMERICA, GULF, SAUDI, CHINA.....10676
PCM Wiring Diagram (3 of 11) For SOUTH AFRICA and EXP.....10677
PCM Wiring Diagram (4 of 11)....10678
PCM Wiring Diagram (5 of 11)....10679
PCM Wiring Diagram (6 of 11) For AUSTRALIA, THAILAND, SOUTH EAST ASIA, LATIN AMERICA, GULF, SAUDI, LATIN AMERICA.....10680
PCM Wiring Diagram (7 of 11) For EC.....10681
PCM Wiring Diagram (8 of 11) For EXPORT and SOUTH AFRICA.....10682
PCM Wiring Diagram (9 of 11) Except EXP and SOUTH AFRICA....10683
PCM Wiring Diagram (10 of 11) For EXPORT and SOUTH AFRICA....10684
PCM Wiring Diagram (11 of 11)....10685
PCM Pinouts....10686
PCM Pinout Table, 32-Way Red Connector – Row “A”....10686
PCM Pinout Table, 32-Way Red Connector – Row “B”....10688
PCM Pinout Table, 32-Way White Connector – Row “C” (For EC)....10689
PCM Pinout Table, 32-Way White Connector – Row “C” (For except EC)....10690
PCM Pinout Table, 32-Way White Connector ‐ Row “D” (For except EXPORT and SOUTH AFRICA)....10691
PCM Pinout Table, 32-Way White Connector ‐ Row “D” (For EXPORT and SOUTH AFRICA)....10692
PCM Pinout Table, 32-Way Blue Connector ‐ Row “E” (For except EXPORT and SOUTH AFRICA)....10693
PCM Pinout Table, 32-Way Blue Connector ‐ Row “E” (For EXPORT and SOUTH AFRICA)....10695
PCM Pinout Table, 32-Way Blue Connector ‐ Row “F”....10696
Component Locators....10697
Engine Component Locator (This illustration is based on RHD model.)....10697
Engine Component Locator Table....10698
Engine Component Locator Table....10700
Undercarriage Component Locator....10701
Undercarriage Component Locator Table (Automatic Transmission)....10701
Undercarriage Component Locator Table (Manual Transmission)....10702
Fuse and Relay Panel (Underhood Electrical Center)....10702
Sensors and Miscellaneous Component Locators....10703
Diagnosis....10706
Strategy-Based Diagnostics....10706
DTC Stored....10706
No DTC....10706
No Matching Symptom....10706
Intermittents....10706
No Trouble Found....10706
Verifying Vehicle Repair....10706
General Service Information....10707
OBD Serviceablity Issues....10707
Maintenance Schedule....10707
Visual / Physical Engine Compartment Inspection....10707
Basic Knowledge of Tools Required....10707
Serial Data Communications....10707
Class II Serial Data Communications....10707
On-Board Diagnostic (OBD)....10708
On-Board Diagnostic Tests....10708
Comprehensive Component Monitor Diagnostic Operation....10708
Common OBD Terms....10709
The Diagnostic Executive....10709
DTC Types....10710
Verifying Vehicle Repair....10711
Reading Diagnostic Trouble Codes Using A Tech 2....10711
Tech 2....10712
Tech 2 Features....10712
Getting Started....10713
Operating Procedure (For Example)....10713
DTC Modes....10714
DTC Information Mode....10715
Injector Balance Test....10715
EGR Control Test....10716
Idle Air Control System Test....10717
Primary System-Based Diagnostic....10719
Primary System-Based Diagnostic....10719
Fuel Control Heated Oxygen Sensor....10719
HO2S Heater....10719
Fuel Trim System Monitor Diagnostic Operation....10719
Fuel Trim System Monitor Diagnostic Operation....10719
Fuel Trim Cell Diagnostic Weights....10719
On-Board Diagnostic (OBD) System Check....10720
A/C Clutch Control Circuit Diagnosis....10723
Electronic Ignition System Diagnosis....10729
Fuel Metering System Check....10729
Idle Air Control (IAC) Valve....10729
Fuel System Pressure Test....10729
Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure....10729
Knock Sensor Diagnosis....10734
Powertrain Control Module (PCM) Diagnosis....10734
Multiple PCM Information Sensor DTCS Set....10734
Exhaust Gas Recirculation (EGR) Diagnosis (For except EXPORT and SOUTH AFRICA)....10737
Engine Tech 2 Data Definitions and Ranges....10737
Typical Scan Data Values....10739
No Malfunction Indicator Lamp (MIL)....10743
Malfunction Indicator Lamp (MIL) “ON” Steady....10746
Engine Cranks But Will Not Run....10748
Fuel System Electrical Test....10754
Fuel System Diagnosis....10757
Idle Air Control (IAC) System Check....10762
Knock Sensor (KS) System Check (Engine Knock, Poor Performance, or Poor Economy)....10764
Exhaust Gas Recirculation (EGR) System Check....10766
Manifold Absolute Pressure (MAP) Output Check....10768
PCM Diagnostic Trouble Codes....10770
Diagnostic Trouble Code (DTC) P0101 MAF System Performance....10773
Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency....10776
Diagnostic Trouble Code (DTC) P0103 MAF Sensor Circuit High Frequency....10779
Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage....10781
Diagnostic Trouble Code (DTC) P0108 MAP Sensor Circuit High Voltage....10784
Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage....10787
Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage....10790
Diagnostic Trouble Code (DTC) P0117 ECT Sensor Circuit Low Voltage....10793
Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage....10796
Diagnostic Trouble Code (DTC) P0121 TP System Performance....10799
Diagnostic Trouble Code (DTC) P0122 TP Sensor Circuit Low Voltage....10802
Diagnostic Trouble Code (DTC) P0123 TP Sensor Circuit High Voltage....10805
Diagnostic Trouble Code (DTC) P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1....10808
Diagnostic Trouble Code (DTC) P0132 HO2S Circuit High Voltage Bank 1 Sensor 1....10811
Diagnostic Trouble Code (DTC) P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1....10814
Diagnostic Trouble Code (DTC) P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1....10817
Diagnostic Trouble Code (DTC) P0152 HO2S Circuit HIGH Voltage Bank 2 Sensor 1....10820
Diagnostic Trouble Code (DTC) P0171 Fuel Trim System Lean Bank 1....10823
Diagnostic Trouble Code (DTC) P0172 Fuel Trim System Rich Bank 1....10827
Diagnostic Trouble Code (DTC) P0174 Fuel Trim System Lean Bank 2....10831
Diagnostic Trouble Code (DTC) P0175 Fuel Trim System Rich Bank 2....10835
Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit....10839
Diagnostic Trouble Code (DTC) P0202 Injector 2 Control Circuit....10842
Diagnostic Trouble Code (DTC) P0203 Injector 3 Control Circuit....10845
Diagnostic Trouble Code (DTC) P0204 Injector 4 Control Circuit....10848
Diagnostic Trouble Code (DTC) P0205 Injector 5 Control Circuit....10851
Diagnostic Trouble Code (DTC) P0206 Injector 6 Control Circuit....10854
Diagnostic Trouble Code (DTC) P0325 KS Module Circuit....10857
Diagnostic Trouble Code (DTC) P0327 KS Sensor Circuit....10859
Diagnostic Trouble Code (DTC) P0336 58X Reference Signal Circuit....10862
Diagnostic Trouble Code (DTC) P0337 CKP Sensor Circuit Low Frequency....10864
Diagnostic Trouble Code (DTC) P0341 CMP Sensor Circuit Performance....10867
Diagnostic Trouble Code (DTC) P0342 CMP Sensor Circuit Low....10871
Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit....10875
Diagnostic Trouble Code (DTC) P0352 Ignition 2 Control Circuit....10878
Diagnostic Trouble Code (DTC) P0353 Ignition 3 Control Circuit....10881
Diagnostic Trouble Code (DTC) P0354 Ignition 4 Control Circuit....10884
Diagnostic Trouble Code (DTC) P0355 Ignition 5 Control Circuit....10887
Diagnostic Trouble Code (DTC) P0356 Ignition 6 Control Circuit....10890
Diagnostic Trouble Code (DTC) P0402 EGR Pintle Crank Error....10893
Diagnostic Trouble Code (DTC) P0404 EGR Open Stuck....10895
Diagnostic Trouble Code (DTC) P0405 EGR Low Voltage....10897
Diagnostic Trouble Code (DTC) P0406 EGR High Voltage....10900
Diagnostic Trouble Code (DTC) P0502 VSS Circuit Low Input....10903
Diagnostic Trouble Code (DTC) P0562 System Voltage Low....10906
Diagnostic Trouble Code (DTC) P0563 System Voltage High....10908
Diagnostic Trouble Code (DTC) P0601 PCM Memory....10909
Diagnostic Trouble Code (DTC) P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1....10910
Diagnostic Trouble Code (DTC) P1171 Fuel System Lean During Acceleration....10914
Diagnostic Trouble Code (DTC) P1380 ABS Rough Road ABS System Fault....10917
Diagnostic Trouble Code (DTC) P1404 EGR Closed Stuck....10918
Diagnostic Trouble Code (DTC) P1508 IAC System Low RPM....10920
Diagnostic Trouble Code (DTC) P1509 IAC System High RPM....10923
Diagnostic Trouble Code (DTC) P1618 Serial Peripheral Interface (SPI) PCM Interprocessor Communication Error....10926
Diagnostic Trouble Code (DTC) P1625 PCM Unexpected Reset....10927
Diagnostic Trouble Code (DTC) P1640 Driver-1-Input High Voltage....10928
Symptom Diagnosis....10931
Default Matrix Table....10957
Camshaft Position (CMP) Sensor....10960
Crankshaft Position (CKP) Sensor....10961
Engine Coolant Temperature (ECT) Sensor....10961
Heated Oxygen Sensor (HO2S)....10962
Intake Air Temperature (IAT) Sensor....10964
Knock Sensor (KS)....10965
Mass Air Flow (MAF) Sensor....10966
Manifold Absolute Pressure (MAP) Sensor....10966
Malfunction Indicator Lamp (MIL)....10967
Powertrain Control Module (PCM)....10967
EEPROM....10969
Power Steering Pressure (PSP) Switch....10969
Throttle Position (TP) Sensor....10970
Vehicle Speed Sensor (VSS)....10971
Air Cleaner/Air Filter....10972
Idle Air Control (IAC) Valve....10973
Common Chamber....10974
Accelerator Cable Assembly....10974
Accelerator Pedal Replacement....10977
Fuel Filter Cap....10979
Fuel Filter....10979
Fuel Gauge Unit....10982
Fuel Injectors....10983
Fuel Pressure Regulator....10984
Fuel Metering System....10986
Fuel Pump Assembly....10987
Fuel Pump Relay....10988
Fuel Rail Assembly....10988
Fuel Tank....10990
Throttle Body (TB)....10992
Electronic Ignition System....10993
Catalytic Converter....10994
Air Conditioning Relay....10994
EVAP Canister Hoses....10995
EVAP Canister....10995
EVAP Canister Purge Solenoid....10996
Fuel Tank Vent Valve....10997
Linear Exhaust Gas Recirculation (EGR) Valve....10997
Positive Crankcase Ventilation (PCV) Valve....10998
Wiring and Connectors....10999
PCM Connectors and Terminals....10999
Wire Harness Repair: Twisted Shielded Cable....10999
Twisted Leads....11000
Weather-Pack Connector....11001
Com-Pack III....11002
Metri-Pack....11002
General Description....11004
General Description (PCM and Sensors)....11004
58X Reference PCM Input....11004
A/C Request Signal....11004
Crankshaft Position (CKP) Sensor....11004
Camshaft Position (CMP) Sensor and Signal....11004
Engine Coolant Temperature (ECT) Sensor....11004
Electrically Erasable Programmable Read Only Memory (EEPROM)....11005
Fuel Control Heated Oxygen Sensors....11005
Intake Air Temperature (IAT) Sensor....11005
Knock Sensor....11006
Linear Exhaust Gas Recirculation (EGR) Control....11006
Mass Air Flow (MAF) Sensor....11006
Manifold Absolute Pressure (MAP) Sensor....11007
Powertrain Control Module (PCM)....11007
PCM Function....11007
PCM Components....11008
PCM Voltage Description....11008
PCM Input/Outputs....11008
PCM Service Precautions....11008
Reprogramming The PCM....11008
Throttle Position (TP) Sensor....11008
Transmission Fluid Temperature (TFT) Sensor....11009
Transmission Range Switch....11009
Vehicle Speed Sensor (VSS)....11009
Use of Circuit Testing Tools....11009
Aftermarket Electrical and Vacuum Equipment....11009
Electrostatic Discharge Damage....11010
Upshift Lamp....11010
General Description (Air Induction)....11010
Air Induction System....11010
General Description (Fuel Metering)....11010
Acceleration Mode....11010
Accelerator Controls....11010
Battery Voltage Correction Mode....11010
CMP Signal....11010
Clear Flood Mode....11011
Deceleration Mode....11011
Engine Speed/Vehicle Speed/Fuel Disable Mode....11011
Fuel Cutoff Mode....11011
Fuel Injector....11011
Fuel Metering System Components....11011
Fuel Metering System Purpose....11011
Fuel Pressure Regulator....11012
Fuel Pump Electrical Circuit....11012
Fuel Rail....11012
Idle Air Control (IAC) Valve....11012
Run Mode....11013
Starting Mode....11013
Throttle Body Unit....11013
General Description (Electronic Ignition System)....11013
Camshaft Position (CMP) Sensor....11013
Crankshaft Position (CKP) Sensor....11014
Electronic Ignition....11014
Ignition Coils....11014
Ignition Control....11014
Ignition Control PCM Output....11016
Knock Sensor (KS) PCM Input....11016
Powertrain Control Module (PCM)....11016
Spark Plug....11016
A/C Clutch Diagnosis....11018
A/C Clutch Circuit Operation....11018
A/C Clutch Circuit Purpose....11018
A/C Request Signal....11018
General Description (Exhaust Gas Recirculation (EGR) System)....11018
EGR Purpose....11018
Linear EGR Valve....11018
Linear EGR Control....11018
Linear EGR Valve Operation and Results of Incorrect Operation....11018
EGR Pintle Position Sensor....11019
General Description (Positive Crankcase Ventilation (PCV) System)....11019
Crankcase Ventilation System Purpose....11019
Crankcase Ventilation System Operation....11019
6F ENGINE EXHAUST....11024
Service Precaution....11024
General Description....11025
Front Exhaust Pipe....11027
Front Exhaust Pipe and Associated Parts....11027
Removal....11027
Installation....11027
Three Way Catalytic Converter....11028
Removal....11028
Installation....11028
Exhaust Silencer....11029
Exhaust Silencer and Associated Parts....11029
Removal....11029
Installation....11029
Rear Exhaust pipe....11030
Rear Exhaust pipe and Associated Parts....11030
Removal....11030
Installation....11030
Main Data and Specifications....11031
6G ENGINE LUBRICATION....11032
Service Precaution....11032
General Description....11033
Oil Pump....11034
Oil Pump and Associated Parts....11034
Inspection and Repair....11035
Reassembly....11036
Oil Pan and Crankcase....11038
Removal....11038
Installation....11038
Oil Pump....11041
Removal....11041
Installation....11041
Oil Pump Oil Seal....11043
Removal....11043
Installation....11043
Oil Filter....11044
Removal....11044
Installation....11044
Main Data and Specification....11045
Special Tool....11046
6H ENGINE SPEED CONTROL SYSTEM....11047
Service Precaution....11047
Accelerator Pedal Control Cable....11048
Removal....11048
Inspection....11048
Installation....11048
Adjustment....11048
Accelerator Pedal....11049
Accelerator Pedal and Associated Parts....11049
Removal....11049
Installation....11049
Adjustment....11049
6J INDUCTION....11051
Service Precaution....11051
Air Cleaner Element....11052
Removal....11052
Inspection....11052
Installation....11052
Sec.6 ENGINE(32bit)....11053
6A ENGINE MECHANICAL....11053
Service Precaution....11054
General Description....11055
Engine Diagnosis....11056
Cylinder Head Cover LH....11071
Removal....11071
Installation....11072
Cylinder Head Cover RH....11073
Removal....11073
Installation....11073
Common Chamber....11074
Removal....11074
Installation....11074
Exhaust Manifold LH....11076
Removal....11076
Installation....11076
Exhaust Manifold RH....11077
Removal....11077
Installation....11077
Crankshaft Pulley....11078
Removal....11078
Installation....11078
Timing Belt....11079
Removal....11079
Installation....11080
Camshaft....11084
Removal....11084
Installation....11085
Cylinder Head....11087
Removal....11087
Installation....11087
Valve Stem Oil Controller , Valve Spring and Valve Guide....11089
Removal....11089
Installation....11089
Piston, Piston Ring and Connecting Rod....11090
Removal....11090
Installation....11091
Crankshaft and Main Bearings....11092
Removal....11092
Installation....11093
Rear Oil Seal....11097
Removal....11097
Installation....11097
Engine Assembly....11098
Removal....11098
Installation....11099
Cylinder Head....11101
Cylinder Head and Associated Parts....11101
Disassembly....11102
Clean....11102
Inspection and Repair....11102
Reassembly....11103
Valve Spring, Oil Controller, Valve, Valve Guide....11105
Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts....11105
Disassembly....11105
Inspection and Repair....11106
Reassembly....11109
Camshaft....11112
Camshaft and Associated Parts....11112
Disassembly....11112
Inspection and Repair....11113
Reassembly....11115
Crankshaft....11119
Crankshaft and Associated Parts....11119
Disassembly....11119
Inspection and Repair for Bearings....11120
Inspection and Repair for Crankshaft....11122
Reassembly....11123
Piston and Connecting Rod....11127
Piston, Connecting Rod and Associate Parts....11127
Disassembly....11127
Inspection and Repair....11128
Reassembly....11132
Cylinder Block....11134
Cylinder Block and Associated Parts....11134
Disassembly....11134
Inspection and Repair....11135
Reassembly....11136
Main Data and Specification....11139
Special Tool....11145
6B ENGINE COOLING....11147
Service Precaution....11147
General Description....11148
Diagnosis....11151
Draining and Refilling Cooling System....11152
Water Pump....11153
Water Pump and Associated Parts....11153
Removal....11153
Inspection....11153
Installation....11153
Thermostat....11154
Thermostat and Associated Parts....11154
Removal....11154
Inspection....11154
Installation....11154
Radiator....11155
Radiator and Associated Parts....11155
Removal....11155
Inspection....11156
Installation....11157
Drive Belt and Cooling Fan....11158
Drive Belt and Associated Parts....11158
Inspection....11158
Installation....11158
Main Data and Specifications....11159
Special Tool....11160
6C ENGINE FUEL....11161
Service Precaution....11161
General Description....11162
Fuel Metering....11163
Fuel Filter....11164
Fuel Filter and Associated Parts....11164
Removal....11164
Inspection....11164
Installation....11165
Inspection....11165
In–Tank Fuel Filter....11165
Fuel Pump Flow Test....11165
Fuel Pump....11166
Fuel Pump and Associated Parts....11166
Removal....11166
Installation....11166
Fuel Pump Relay....11167
General Description....11167
Fuel Tank....11167
Fuel Tank and Associated Parts....11167
Removal....11167
Installation....11168
Fuel Tube / Quick – Connect Fittings....11168
Precautions....11168
Cautions During Work....11168
Removal....11168
Reuse of Quick–Connector....11170
Assembling Advice....11170
Fuel Gauge Unit....11171
Fuel Gauge Unit and Associated Parts....11171
Removal....11171
Installation....11171
Fuel Filler Cap....11172
General Description....11172
Inspection....11172
Main Data and Specifications....11173
6D1 ENGINE ELECTRICAL....11174
Service Precaution....11174
Battery....11175
General Description....11175
Diagnosis....11175
Battery Charging....11176
Jump Starting....11176
Battery Removal....11177
Battery Installation....11177
Main Data and Specifications....11178
6D2 IGNITION SYSTEM....11179
Service Precaution....11179
General Description....11180
Diagnosis....11180
Ignition Coil....11181
Removal....11181
Inspection and Repair....11181
Installation....11181
Spark Plug....11183
Removal....11183
Inspection and Repair....11183
Installation....11183
Crankshaft Position Sensor....11184
Removal....11184
Installation....11184
Main Data and Specifications....11185
6D3 STARTING AND CHARGING SYSTEM....11186
Service Precaution....11186
Starting System....11187
General Description....11187
Diagnosis....11189
Starter....11190
Removal....11190
Installation....11190
Disassembled View....11191
Disassembly....11192
Inspection and Repair....11194
Reassembly....11198
Main Data and Specifications....11200
Charging System....11203
General Description....11203
General On–Vehicle Inspection....11203
Generator....11204
Removal....11204
Inspection....11204
Installation....11204
Disassembled View....11205
Disassembly....11206
Inspection and Repair....11208
Reassembly....11210
Bench Test....11210
Main Data and Specifications....11212
6E ENGINE DRIVEABILITY AND EMISSIONS....11213
Specifications....11218
Tightening Specifications....11218
Diagrams and Schematics....11219
PCM Wiring Diagram (1 of 7)....11219
PCM Wiring Diagram (2 of 7)....11220
PCM Wiring Diagram (3 of 7)....11221
PCM Wiring Diagram (4 of 7)....11222
PCM Wiring Diagram (5 of 7)....11223
PCM Wiring Diagram (6 of 7)....11224
PCM Wiring Diagram (7 of 7)....11225
PCM Pinouts....11226
PCM Pinout Table, 80-Way Blue Connector – Row “F1 ~ 20”....11226
PCM Pinout Table, 80-Way Blue Connector – Row “F20 ~ 40”....11227
PCM Pinout Table, 80-Way Blue Connector – Row “F41 ~ 60”....11229
PCM Pinout Table, 80-Way Blue Connector – Row “F61 ~ 80”....11231
PCM Pinout Table, 80-Way Red Connector – Row “S1 ~ 20”....11233
PCM Pinout Table, 80-Way Red Connector – Row “S21 ~ 40”....11235
PCM Pinout Table, 80-Way Red Connector – Row “S41 ~ 60”....11237
PCM Pinout Table, 80-Way Red Connector – Row “S61 ~ 80”....11239
Component Locators....11241
Undercarriage Component Locator....11243
Fuse and Relay Panel (Underhood Electrical Center)....11244
Sensors and Miscellaneous Component Locators....11245
Diagnosis....11247
Strategy-Based Diagnostics....11247
DTC Stored....11247
No DTC....11247
No Matching Symptom....11247
Intermittents....11247
No Trouble Found....11247
Verifying Vehicle Repair....11247
General Service Information....11248
OBD Serviceablity Issues....11248
Visual / Physical Engine Compartment Inspection....11248
Basic Knowledge of Tools Required....11248
Serial Data Communications....11249
Class 2 Serial Data Communications....11249
On-Board Diagnostic (OBD)....11249
On-Board Diagnostic Tests....11249
Comprehensive Component Monitor Diagnostic Operation....11249
Common OBD Terms....11250
The Diagnostic Executive....11250
DTC Types....11251
Verifying Vehicle Repair....11253
Reading Diagnostic Trouble Codes Using The Tech 2 Scan Tool....11253
Tech 2....11254
Tech 2 Features....11255
Getting Started....11255
Operating Procedure (For Example)....11256
DTC Modes....11257
DTC Information Mode....11257
Miscellaneous Test....11258
Lamps Test....11258
Relays Test....11260
EVAP Test....11261
Fuel System Test....11262
Instruments Test....11264
EGR Control Test....11265
Variable Intake Manifold Solenoid Test....11266
Injector Balance Test....11267
Plotting Snapshot Graph....11268
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)....11269
Flow Chart for Snapshot Replay (Plotting Graph)....11270
Primary System-Based Diagnostic....11271
Primary System-Based Diagnostic....11271
Fuel Control Heated Oxygen Sensor....11271
HO2S Heater....11271
Catalyst Monitor Heated Oxygen Sensors and Diagnostic Operation....11271
Misfire Monitor Diagnostic Operation....11272
Misfire Monitor Diagnostic Operation....11272
Misfire Counters....11272
Fuel Trim System Monitor Diagnostic Operation....11273
Fuel Trim System Monitor Diagnostic Operation....11273
Fuel Trim Cell Diagnostic Weights....11273
On-Board Diagnostic (OBD) System Check....11274
Circuit Description....11274
Diagnostic Aids....11274
Test Description....11274
A/C Clutch Control Circuit Diagnosis....11277
Circuit Description....11277
Diagnostic Aids....11277
A/C Clutch Diagnosis....11278
Electronic Ignition System Diagnosis....11282
Visual Check of The Evaporative Emission Canister....11282
Fuel Metering System Check....11282
Fuel System Pressure Test....11282
Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure....11282
Test Description....11282
Injector Coil Test Procedure(Steps 1-6) and Injector Balance Test Procedure(Steps 7-11)....11283
Powertrain Control Module (PCM) Diagnosis....11287
Multiple PCM Information Sensor DTCs Set....11287
Circuit Description....11287
Diagnostic Aids....11287
Exhaust Gas Recirculation (EGR) Diagnosis....11290
Engine Tech 2 Data Definitions and Ranges....11290
Typical Scan Data Values....11292
Test Conditions....11292
No Malfunction Indicator Lamp (MIL)....11298
Circuit Description....11298
Diagnostic Aids....11298
Malfunction Indicator Lamp (MIL) “ON” Steady....11301
Circuit description....11301
Diagnostic Aids....11301
No Service Vehilce Soon (SVS) Lamp....11303
Circuit Description....11303
Diagnostic Aids....11303
Service Vehicle Soon (SVS) Lamp “ON” Steady....11306
Circuit description....11306
Diagnostic Aids....11306
Engine Cranks But Will Not Run....11308
Circuit Description....11310
Diagnostic Aids....11310
Test Description....11310
Fuel System Electrical Test....11315
Circuit Description....11316
Diagnostic Aids....11316
Test Description....11316
Fuel Pressure Relief Procedure....11316
Electric Throttle Control (ETC) System Check....11319
Circuit Description....11320
Diagnostic Aids....11320
Test Description....11320
Fuel System Diagnosis....11323
Circuit Description....11324
Test Description....11324
Fuel Pressure Relief Procedure....11325
Exhaust Gas Recirculation (EGR) System Check....11328
Circuit Description....11328
Manifold Absolute Pressure (MAP) Output Check....11330
Circuit Description....11330
Evaporative (EVAP) Emissions Canister Purge Valve Check....11332
Circuit Description....11332
Diagnostic Aids....11332
PCM Diagnostic Trouble Codes....11335
DTC P0101 MAF System Performance....11339
DTC P0102 MAF Sensor Circuit Low Frequency....11342
DTC P0103 MAF Sensor Circuit High Frequency....11345
DTC P0106 MAP System Performance....11347
DTC P0107 MAP Sensor Circuit Low Voltage....11350
DTC P0108 MAP Sensor Circuit High Voltage....11353
DTC P0112 IAT Sensor Circuit Low Voltage....11356
DTC P0113 IAT Sensor Circuit High Voltage....11359
DTC P0117 ECT Sensor Circuit Low Voltage....11362
DTC P0118 ECT Sensor Circuit High Voltage....11365
DTC P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1....11368
DTC P0132 HO2S Circuit High Voltage Bank 1 Sensor 1....11371
DTC P0133 HO2S Slow Response Bank 1 Sensor 1....11374
DTC P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1....11378
DTC P0135 HO2S Heater Circuit Bank 1 Sensor 1....11381
DTC P0137 HO2S Circuit Low Voltage Bank 1 Sensor 2....11384
DTC P0138 HO2S Circuit High Voltage Bank 1 Sensor 2....11387
DTC P0140 HO2S Circuit Insufficient Activity Bank 1 Sensor 2....11390
DTC P0141 HO2S Heater Circuit Bank 1 Sensor 2....11393
DTC P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1....11396
DTC P0152 HO2S Circuit High Voltage Bank 2 Sensor 1....11399
DTC P0153 HO2S Slow Response Bank 2 Sensor 1....11402
DTC P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1....11406
DTC P0155 HO2S Heater Circuit Open Bank 2 Sensor 1....11409
DTC P0157 HO2S Circuit Low Voltage Bank 2 Sensor 2....11412
DTC P0158 HO2S Circuit High Voltage Bank 2 Sensor 2....11415
DTC P0160 HO2S Circuit Insufficient Activity Bank 2 Sensor 2....11418
DTC P0161 HO2S Heater Circuit Bank 2 Sensor 2....11421
DTC P0171 Fuel Trim System Lean Bank 1....11424
DTC P0172 Fuel Trim System Rich Bank 1....11428
DTC P0174 Fuel Trim System Lean Bank 2....11432
DTC P0175 Fuel Trim System Rich Bank 2....11436
DTC P0201 Injector 1 Control Circuit....11440
DTC P0202 Injector 2 Control Circuit....11443
DTC P0203 Injector 3 Control Circuit....11446
DTC P0204 Injector 4 Control Circuit....11449
DTC P0205 Injector 5 Control Circuit....11452
DTC P0206 Injector 6 Control Circuit....11455
DTC P0300 Engine Misfire Detected....11458
DTC P0325 ION Sensing Module/ION Sensing Knock Intensity Circuit Fault....11462
DTC P0336 58X Reference Signal Circuit....11465
DTC P0337 CKP Sensor Circuit Low Frequency....11468
DTC P0351 Ignition 1 Control Circuit....11471
DTC P0352 Ignition 2 Control Circuit....11474
DTC P0353 Ignition 3 Control Circuit....11477
DTC P0354 Ignition 4 Control Circuit....11480
DTC P0355 Ignition 5 Control Circuit....11483
DTC P0356 Ignition 6 Control Circuit....11486
DTC P0401 EGR Flow Insufficient....11489
DTC P0402 EGR Pintle Crank Error....11492
DTC P0404 EGR Open Stuck....11494
DTC P0405 EGR Low Voltage....11496
DTC P0406 EGR High Voltage....11499
DTC P0420 TWC System Low Efficiency Bank 1....11502
DTC P0430 TWC System Low Efficiency Bank 2....11505
DTC P0444 EVAP Purge Control Circuit Open....11508
DTC P0445 EVAP Purge Control Circuit Short....11510
DTC P0502 VSS Circuit Low Input....11512
DTC P0506 Idle Air Control System Low RPM....11515
DTC P0507 Idle Air Control System High RPM....11518
DTC P0562 System Voltage Low....11521
DTC P0563 System Voltage High....11523
DTC P0565 Cruise Main Switch Circuit Error....11525
DTC P0566 Cruise Cancel Switch Circuit Error....11527
DTC P0567 Cruise Resume Switch Circuit Error....11529
DTC P0568 Cruise Set Switch Circuit Error....11531
DTC P0571 No Brake Switch Signal....11533
DTC P0601 PCM Memory....11535
DTC P0602 PCM Programming Error....11537
DTC P0604 PCM RAM Error....11539
DTC P0606 PCM Internal Performance....11541
DTC P0660 VIM Solenoid Circuit Open....11543
DTC P0662 VIM Solenoid Circuit Short....11545
DTC P1106 MAP Sensor Circuit Intermittent High Voltage....11547
DTC P1107 MAP Circuit Intermittent Low Voltage....11549
DTC P1111 IAT Sensor Circuit Intermittent High Voltage....11551
DTC P1112 IAT Sensor Circuit Intermittent Low Voltage....11554
DTC P1114 ECT Sensor Circuit Intermittent Low Voltage....11556
DTC P1115 ECT Sensor Circuit Intermittent High Voltage....11558
DTC P1120-TPS1 Throttle Position Sensor (TPS1) Circuit Fault....11561
DTC P1125 ETC (Electric throttle control) Limit Per-formance Mode....11564
DTC P1133 HO2S Insufficient Switching Bank 1 Sensor 1....11567
DTC P1134 HO2S Transition Time Ratio Bank 1 Sensor 1....11571
DTC P1153 HO2S Insufficient Switching Bank 2 Sensor 1....11575
DTC P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1....11579
DTC P1167 Fuel System Rich During Decel Fuel Cut Off (Bank 1)....11583
DTC P1169 Fuel System Rich During Decel Fuel Cut Off (Bank 2)....11585
DTC P1171 Fuel System Lean During Acceleration....11587
DTC P1220 Throttle Position Senser2 (TPS2) Circuit Fault....11590
DTC P1221 TPS1 ‐ TPS2 correlation(Circuit Performance)....11593
DTC P1271 APS 1 ‐ 2 Correlation Error....11596
DTC P1272 APS 2 ‐ 3 Correlation Error....11599
DTC P1273 APS 1 ‐ 3 Correlation Error....11602
DTC P1275 APS 1 Circuit Fault....11605
DTC P1280 APS 2 Circuit Fault....11607
DTC P1285 APS 3 Circuit Fault....11609
DTC P1290 ETC Forced Idle Mode....11611
DTC P1295 Power Management Mode....11613
DTC P1299 ETC Forced Engine Shutdown Mode....11615
DTC P1310 ION Sensing Module Diagnosis....11617
DTC P1311 ION Sensing Module SEC Line 1 Circuit Fault....11620
DTC P1312 ION Sensing Module SEC Line 2 Circuit Fault....11623
DTC P1326 ION Sensing Module Combustion Quality Input Circuit Fault....11626
DTC P1340 ION Sensing Module Cylinder ID Fault (Cylinder Synchronization Fail)....11629
DTC P1404 EGR Stuck Closed....11632
DTC P1514 TPS - MAF Correlation Error....11635
DTC P1515 Command - Actual TPS Correlation Error....11639
DTC P1516 Command - Actual TPS Correlation Error....11642
DTC P1523 Actuator Control Return Performance....11645
DTC P1574 Brake Switch No Operation....11648
DTC P1626 No response from immobilizer....11650
DTC P1631 Received response was not correct....11652
DTC P1635 Reference Voltage # 1 Circuit Fault....11654
DTC P1636 PCM RAM Stack....11656
DTC P1639 Reference Voltage # 2 Circuit Fault....11657
DTC P1640 Driver-1-Output Circuit Fault (ODM)....11659
DTC P1648 Received incorrect security code....11661
DTC P1649 Security code & security key not programmed....11662
DTC P1650 Quad Driver Module “A” Fault....11664
Symptom Diagnosis....11667
Default Matrix Table....11696
On Vehicle Service Crankshaft Position (CKP) Sensor....11699
Engine Coolant Temperature....11699
Heated Oxygen Sensor (HO2S)....11700
Intake Air Temperature (IAT) Sensor....11703
ION Sensing Module....11703
Mass Air Flow (MAF) Sensor....11704
Manifold Absolute Pressure (MAP) Sensor....11705
Malfunction Indicator Lamp (MIL)....11706
Reduced Power Lamp....11706
Powertrain Control Module (PCM)....11706
Service Precaution....11706
Removal Procedure....11706
Installation Procedure....11707
EEPROM....11708
Throttle Position (TP) Sensor....11708
Vehicle Speed Sensor (VSS)....11709
Air Cleaner/Air Filter....11710
Common Chamber....11710
Accelerator Pedal Replacement....11711
Accelerator Position Sensor Replacement....11712
Accelerator Position Sensor Adjustment....11712
Fuel Filler Cap....11713
Fuel Filter....11713
Fuel Gauge Unit....11715
Fuel Injectors....11715
Fuel Metering System....11716
Fuel Pump Assembly....11717
Fuel Pump Relay....11717
Fuel Rail Assembly....11718
Fuel Tank....11719
Throttle Body (TB)....11719
Electronic Ignition System....11721
Catalytic Converter....11722
Air Conditioning Thermo Relay....11722
EVAP Canister Hoses....11722
EVAP Canister....11723
EVAP Canister Purge Solenoid (Purge Duty Solenoid Valve)....11724
Fuel Tank Vent Valve (Vent Solenoid Valve)....11724
Linear Exhaust Gas Recirculation (EGR) Valve....11725
Positive Crankcase Ventilation (PCV) Valve....11726
PCV Valve....11726
Wiring and Connectors....11726
PCM Connectors and Terminals....11727
Wire Harness Repair: Twisted Shielded Cable....11727
Twisted Leads....11728
Weather-Pack Connector....11729
Com-Pack III....11730
Metri-Pack....11731
General Description (PCM and Sensors)....11732
58X Reference PCM Input....11732
A/C Request Signal....11732
Crankshaft Position (CKP) Sensor....11732
Engine Coolant Temperature (ECT) Sensor....11732
Electrically Erasable Programmable Read Only Memory (EEPROM)....11732
Fuel Control Heated Oxygen Sensors....11732
Catalyst Monitor Heated Oxygen Sensors....11733
Intake Air Temperature (IAT) Sensor....11733
Linear Exhaust Gas Recirculation (EGR) Control....11734
Mass Air Flow (MAF) Sensor....11734
Manifold Absolute Pressure (MAP) Sensor....11734
Powertrain Control Module (PCM)....11735
PCM Function....11735
PCM Components....11735
PCM Voltage Description....11735
PCM Input/Outputs....11735
PCM Service Precautions....11736
Reprogramming The PCM....11736
Throttle Position (TP) Sensor....11736
Transmission Fluid Temperature (TFT) Sensor....11736
Transmission Range Switch (Mode Switch)....11736
Vehicle Speed Sensor (VSS)....11736
Use of Circuit Testing Tools....11736
Aftermarket Electrical and Vacuum Equipment....11737
Electrostatic Discharge Damage....11737
General Description (Air Induction)....11737
Air Induction System....11737
General Description (Fuel Metering)....11738
Acceleration Mode....11738
Battery Voltage Correction Mode....11738
Clear Flood Mode....11738
Deceleration Mode....11738
Engine Speed/Vehicle Speed/Fuel Disable Mode....11738
Fuel Cutoff Mode....11738
Fuel Injector....11738
Fuel Metering System Components....11738
Fuel Metering System Purpose....11738
Fuel Pressure Regulator....11739
Fuel Pump Electrical Circuit....11739
Fuel Rail....11739
Run Mode....11739
Starting Mode....11739
Throttle Body Unit....11740
General Description (Electronic Ignition System)....11740
Crankshaft Position (CKP) Sensor....11740
Electronic Ignition....11740
Ignition Coils....11740
Ignition Control....11740
Ignition Control PCM Output....11741
Powertrain Control Module (PCM)....11741
Spark Plug....11742
A/C Clutch Diagnosis....11743
A/C Clutch Circuit Operation....11743
A/C Clutch Circuit Purpose....11743
A/C Request Signal....11743
General Description (Exhaust Gas Recirculation (EGR) System)....11743
EGR Purpose....11743
Linear EGR Valve....11744
Linear EGR Control....11744
Linear EGR Valve Operation and Results of Incorrect Operation....11744
EGR Pintle Position Sensor....11744
General Description (Positive Crankcase Ventilation (PCV) System)....11744
Crankcase Ventilation System Purpose....11744
Crankcase Ventilation System Operation....11744
Special Tools....11746
6F ENGINE EXHAUST....11747
General Description....11748
Front Exhaust Pipe....11749
Front Exhaust Pipe and Associated Parts....11749
Removal....11749
Installation....11749
Three Way Catalytic Converter LH....11750
Removal....11750
Installation....11750
Three Way Catalytic Converter RH....11751
Removal....11751
Installation....11751
Exhaust Silencer....11752
Exhaust Silencer and Associated Parts....11752
Removal....11752
Installation....11753
Rear Exhaust pipe....11754
Rear Exhaust pipe and Associated Parts....11754
Removal....11754
Installation....11754
Main Data and Specifications....11755
6G ENGINE LUBRICATION....11756
Service Precaution....11756
General Description....11757
Oil Pump....11758
Oil Pump and Associated Parts....11758
Oil Pump and Associated Parts....11759
Inspection and Repair....11759
Reassembly....11760
Oil Pan and Crankcase....11762
Removal....11762
Installation....11762
Oil Pump....11765
Removal....11765
Installation....11765
Oil Pump Oil Seal....11767
Removal....11767
Installation....11767
Oil Filter....11768
Removal....11768
Installation....11768
Main Data and Specification....11769
Special Tool....11770
6H ENGINE SPEED CONTROL SYSTEM....11771
Service Precaution....11771
Accelerator Pedal....11772
Accelerator Pedal and Associated Parts....11772
Removal....11772
Installation....11772
6J INDUCTION....11773
Service Precaution....11773
Air Cleaner Element....11774
Removal....11774
Inspection....11774
Installation....11774
Sec.6 ENGINE(4JX1)....11775
6A ENGINE MECHANICAL....11775
GENERAL DESCRIPTION....11776
SERVICE INFORMATION....11777
SERVICE STANDARD....11780
SERVICING....11783
TIGHTENING TORQUE....11788
SPECIAL TOOLS....11799
ENGINE ASSEMBLY....11802
ENGINE MOUNT (RH)....11804
ENGINE MOUNT (LH)....11805
INTERCOOLER....11806
CYLINDER HEAD COVER....11807
INTAKE MANIFOLD....11809
EXHAUST MANIFOLD....11810
TURBOCHARGER....11812
CYLINDER HEAD....11815
CYLINDER HEAD GASKET....11817
CAMSHAFT....11821
TIMING GEAR....11826
VALVE STEM SEAL, VALVE SPRING AND ADJUSTER....11834
VALVE CLEARANCE ADJUSTMENT....11841
OIL RAIL AND INJECTOR....11843
CRANK CASE....11846
CRANKSHAFT....11848
PISTON AND CONNECTING ROD....11858
CYLINDER BLOCK....11866
OIL PUMP ASSEMBLY....11872
OIL FILTER CARTRIDGE....11873
OIL COOLER....11873
6B ENGINE COOLING....11875
GENERAL DESCRIPTION....11876
ON-VEHICLE SERVICE....11880
WATER PUMP....11880
THERMOSTAT....11881
RADIATOR....11883
DRIVE BELT ADJUSTMENT....11885
6C ENGINE FUEL....11887
GENERAL DESCRIPTION....11887
ON-VEHICLE SERVICE....11893
FUEL FILTER ASSEMBLY....11893
FUEL FILTER CARTRIDGE....11893
INJECTOR....11895
FUEL PUMP PIPE....11899
HIGH PRESSURE OIL PUMP....11901
FUEL TANK....11906
FUEL GAUGE UNIT....11907
FUEL FILLER CAP....11907
6D ENGINE ELECTRICAL....11909
BATTERY....11909
GENERAL DESCRIPTION....11909
DIAGNOSIS....11909
ON-VEHICLE SERVICE....11911
MAIN DATA AND SPECIFICATIONS....11912
STARTING SYTEM....11913
GENERAL DESCRIPTION....11913
ON-VEHICLE SERVICE....11915
STARTER....11915
UNIT REPAIR....11916
CHARGING SYSTEM....11923
GENERAL DESCRIPTION....11923
DIAGNOSIS....11924
UNIT REPAIR....11925
MAIN DATA AND SPECIFICATIONS....11930
QOS4 PREHEATING SYSTEM....11931
GENERAL DESCRIPTION....11931
SYSTEM DIAGRAM....11931
INSPECTION ON QOS4 SYSTEM OPERATION....11932
6E ENGINE DRIVEABILITY AND EMISSIONS....11935
Specification....11941
Tightening Specifications....11941
Diagrams and Schematics....11942
ECM Wiring Diagram (1 of 6)....11942
ECM Wiring Diagram (2 of 6)....11943
ECM Wiring Diagram (3 of 6)....11944
ECM Wiring Diagram (4 of 6)....11945
ECM Wiring Diagram (5 of 6)....11946
ECM Wiring Diagram (6 of 6)....11947
ECM Pinouts....11948
ECM Pinout Table, 32-Way Connector ‐ J1 RED ‐ Upper....11948
ECM Pinout Table, 32-Way Connector ‐ J1 RED ‐ Lower....11949
ECM Pinout Table, 32-Way Connector ‐ J2 BLUE ‐ Upper....11950
ECM Pinout Table, 32-Way Connector ‐ J2 BLUE ‐ Lower....11951
ECM Pinout Table, 5-Way Connector ‐ J3....11952
Component Locator....11953
Sensors and Miscellaneous Component Locators....11955
Abbreviations Charts....11957
Diagnosis....11958
Strategy-Based Diagnostics....11958
DTC Stored....11958
No DTC....11958
No Matching Symptom....11958
Intermittents....11958
No Trouble Found....11958
Verifying Vehicle Repair....11958
General Service Information....11959
Serviceability Issues....11959
Visual/Physical Engine Compartment Inspection....11959
Basic Knowledge of Tools Required....11959
Serial Data Communications....11959
Class II Serial Data Communications....11959
On-Board Diagnostic (OBD)....11959
On-Board Diagnostic Tests....11959
Comprehensive Component Monitor Diagnostic Operation....11959
Common OBD Terms....11960
The Diagnostic Executive....11960
DTC Types....11960
Verifying Vehicle Repair....11961
Reading Flash Diagnostic Trouble Codes....11961
Reading Diagnostic Trouble Codes Using a TECH 2....11962
Tech 2 Scan Tool....11963
Getting Started....11964
DTC Modes....11966
DTC Information Mode....11966
Injector Test....11966
EGR Valve Test....11966
Rail Pressure Control Valve Test....11966
Injector Balance Test....11966
Data Programming in Case of ECM Change....11966
Rail Pressure Sensor Programming....11967
Injector Group Sign Programming (Injector Change)....11967
On-Board Diagnostic (OBD) System Check....11969
Circuit Description....11971
Diagnostic Aids....11971
Engine Control Module ECM Diagnosis....11973
Multiple ECM Information Sensor DTCS Set....11973
Circuit Description....11973
Diagnostic Aids....11973
EGR (Exhaust Gas Recirculation) Diagnosis....11975
Tech 2 Data Definitions and Ranges....11975
Typical Scan Data Values....11975
Test Conditions....11975
4JX1-TC Engine (Automatic and Manual Transmission)....11976
No Malfunction Indicator Lamp (MIL)....11978
Circuit Description....11978
Diagnostic Aids....11978
Malfunction Indicator Lamp (MIL) “ON” Steady....11981
Circuit description....11981
Diagnostic Aids....11981
Engine Cranks But Will Not Run....11983
Circuit Description....11983
Diagnostic Aids....11983
Exhaust Gas Recirculation (EGR) System Check....11986
Circuit Description....11986
ECM Diagnostic Trouble Codes....11988
ECM Diagnostic Trouble Codes....11988
DTC P0107 (Flash DTC 34) MAP Sensor Circuit Low Voltage....11990
Circuit Description....11990
Action Taken When the DTC Sets....11990
Conditions for Clearing the MIL/DTC....11990
Diagnostic Aids....11990
DTC P0108 (Flash DTC 34) MAP Sensor Circuit High Voltage....11992
Circuit Description....11992
Action Taken When the DTC Sets....11992
Conditions for Clearing the MIL/DTC....11992
Diagnostic Aids....11992
DTC P0112 (Flash DTC 23) IAT Sensor Circuit Low Voltage....11994
Circuit Description....11994
Action Taken When the DTC Sets....11994
Conditions for Clearing the MIL/DTC....11994
Diagnostic Aids....11994
Test Description....11995
Intake Air Temperature Sensor....11995
DTC P0113 (Flash DTC 23) IAT Sensor Circuit High Voltage....11996
Circuit Description....11996
Action Taken When the DTC Sets....11996
Conditions for Clearing the MIL/DTC....11996
Diagnostic Aids....11996
Test Description....11997
Manifold Air Temperature Sensor....11997
DTC P0117 (Flash DTC 14) ECT Sensor Low Voltage....11999
Circuit Description....11999
Action Taken When the DTC Sets....11999
Conditions for Clearing the MIL/DTC....11999
Diagnostic Aids....11999
Test Description....11999
Engine Coolant Temperature Sensor....12000
DTC P0118 (Flash DTC 14) ECT Sensor High Voltage....12001
Circuit Description....12001
Action Taken When the DTC Sets....12001
Conditions for Clearing the MIL/DTC....12001
Diagnostic Aids....12001
Test Description....12002
Engine Coolant Temperature Sensor....12002
DTC P0121 (Flash DTC 33) AP Sensor Rationality....12004
Circuit Description....12004
Action Taken When the DTC Sets....12004
Conditions for Clearing the MIL/DTC....12004
Diagnostic Aids....12004
DTC P0122 (Flash DTC 21) AP Sensor Low Voltage....12006
Circuit Description....12006
Action Taken When the DTC Sets....12006
Conditions for Clearing the MIL/DTC....12006
Diagnostic Aids....12006
DTC P0123 (Flash DTC 21) AP Sensor High Voltage....12009
Circuit Description....12009
Action Taken When the DTC Sets....12009
Conditions for Clearing the MIL/DTC....12009
Diagnostic Aids....12009
Test Description....12009
DTC P0182 (Flash DTC 15) FT Sensor Low Voltage....12012
Circuit Description....12012
Action Taken When the DTC Sets....12012
Conditions for Clearing the MIL/DTC....12012
Diagnostic Aids....12012
Test Description....12012
DTC P0183 (Flash DTC 15) FT Sensor High Voltage....12014
Circuit Description....12014
Action Taken When the DTC Sets....12014
Conditions for Clearing the MIL/DTC....12014
Diagnostic Aids....12014
Test Description....12014
DTC P0192 (Flash DTC 63) Rail Pressure Sensor Low Voltage....12016
Circuit Description....12016
Action Taken When the DTC Sets....12016
Conditions for Clearing the MIL/DTC....12016
Diagnostic Aids....12016
DTC P0193 (Flash DTC 63) Rail Pressure Sensor High Voltage....12018
Circuit Description....12018
Action Taken When the DTC Sets....12018
Conditions for Clearing the MIL/DTC....12018
Diagnostic Aids....12018
DTC P1193 (Flash DTC 64) RPCV Circuit Open/Short....12020
Circuit Description....12020
Action Taken When the DTC Sets....12020
Conditions for Clearing the MIL/DTC....12020
Diagnostic Aids....12020
DTC P1194 (Flash DTC 61) Rail Pressure System Low Voltage....12022
Circuit Description....12022
Action Taken When the DTC Sets....12022
Conditions for Clearing the MIL/DTC....12022
Diagnostic Aids....12022
DTC P1195 (Flash DTC 61) Rail Pressure System High Voltage....12024
Circuit Description....12024
Action Taken When the DTC Sets....12024
Conditions for Clearing the MIL/DTC....12024
Diagnostic Aids....12024
DTC P1196 (Flash DTC 62) Rail Pressure System High Warning....12026
Circuit Description....12027
Action Taken When the DTC Sets....12027
Conditions for Clearing the MIL/DTC....12027
Diagnostic Aids....12027
Test Description....12027
DTC P0197 (Flash DTC 16) Oil Temp Sensor Low Voltage....12028
Circuit Description....12028
Action Taken When the DTC Sets....12028
Conditions for Clearing the MIL/DTC....12028
Diagnostic Aids....12028
Test Description....12029
Engine Oil Temperature Sensor....12029
DTC P0198 (Flash DTC 16) Oil Temp Sensor High Voltage....12030
Circuit Description....12030
Action Taken When the DTC Sets....12030
Conditions for Clearing the MIL/DTC....12030
Diagnostic Aids....12030
Test Description....12031
Engine Oil Temperature Sensor....12031
DTC P0201 (Flash DTC 51) Injector # 1 Circuit Fault....12033
Circuit Description....12033
Action Taken When the DTC Sets....12033
Conditions for Clearing the MIL/DTC....12033
Diagnostic Aids....12033
Test Description....12033
Injector Test....12033
DTC P0202 (Flash DTC 52) Injector # 2 Circuit Fault....12035
Circuit Description....12035
Action Taken When the DTC Sets....12035
Conditions for Clearing the MIL/DTC....12035
Diagnostic Aids....12035
Test Description....12035
Injector Test....12035
DTC P0203 (Flash DTC 52) Injector # 3 Circuit Fault....12037
Circuit Description....12037
Action Taken When the DTC Sets....12037
Conditions for Clearing the MIL/DTC....12037
Diagnostic Aids....12037
Test Description....12037
Injector Test....12037
DTC P0204 (Flash DTC 54) Injector # 4 Circuit Fault....12039
Circuit Description....12039
Action Taken When the DTC Sets....12039
Conditions for Clearing the MIL/DTC....12039
Diagnostic Aids....12039
Test Description....12039
Injector Test....12039
DTC P0217 (Flash DTC 22) High Coolant Temp Waring....12041
Circuit Description....12041
Action Taken When the DTC Sets....12041
Conditions for Clearing the MIL/DTC....12041
Diagnostic Aids....12041
Test Description....12041
DTC P1217 (Flash DTC 36) High Oil Temp Warning....12043
Circuit Description....12043
Action Taken When the DTC Sets....12043
Conditions for Clearing the MIL/DTC....12043
Diagnostic Aids....12043
DTC P0219 (Flash DTC 11) Engine Over Speed Warning....12045
Circuit Description....12045
Action Taken When the DTC Sets....12045
Conditions for Clearing the MIL/DTC....12045
Diagnostic Aids....12045
DTC P0336 (Flash DTC 43) CKP (Crank Position) Sensor Out of Synchro....12048
Circuit Description....12048
Action Taken When the DTC Sets....12048
Conditions for Clearing the MIL/DTC....12048
Diagnostic Aids....12048
DTC P0337 (Flash DTC 43) CKP (Crank Position) Sensor No Signal....12050
Circuit Description....12050
Action Taken When the DTC Sets....12050
Conditions for Clearing the MIL/DTC....12050
Diagnostic Aids....12050
DTC P0341 (Flash DTC 41) CMP (Cam Position) Sensor Out of Synchro....12053
Circuit Description....12053
Action Taken When the DTC Sets....12053
Conditions for Clearing the MIL/DTC....12053
Diagnostic Aids....12053
Test Description....12053
DTC P0342 (Flash DTC 41) CMP (Cam Position) Sensor No Signal....12056
Circuit Description....12056
Action Taken When the DTC Sets....12056
Conditions for Clearing the MIL/DTC....12056
Diagnostic Aids....12056
Test Description....12056
DTC P0380 (Flash DTC 66) Glow Relay Circuit Open/Short....12060
Circuit Description....12060
Action Taken When the DTC Sets....12060
Conditions for Clearing the MIL/DTC....12060
Diagnostic Aids....12060
DTC P0381 (Flash DTC 67) Glow Lamp Circuit Open/Short....12062
Circuit Description....12062
Action Taken When the DTC Sets....12062
Conditions for Clearing the MIL/DTC....12062
Diagnostic Aids....12062
DTC P1403 (Flash DTC 32) EGR EVRV Fault....12064
Circuit Description....12064
Diagnostic Aids....12064
Test Description....12064
DTC P1404 (Flash DTC 31) EGR VSV Circuit....12066
Circuit Description....12066
Diagnostic Aids....12066
DTC P0405 (Flash DTC 26) EGR Pressure Sensor Low Voltage....12068
Action Taken When the DTC Sets....12068
Conditions for Clearing the MIL/DTC....12068
Diagnostic Aids....12068
DTC P1405 (Flash DTC 37) EGR EVRV Circuit Open/Short....12070
Circuit Description....12070
Action Taken When the DTC Sets....12070
Conditions for Clearing the MIL/DTC....12070
Diagnostic Aids....12070
DTC P0406 (Flash DTC 26) EGR Pressure Sensor High Voltage....12072
Action Taken When the DTC Sets....12072
Conditions for Clearing the MIL/DTC....12072
Diagnostic Aids....12072
DTC P0475 (Flash DTC 71) EXH #1 VSV Circuit....12074
Circuit Description....12074
Action Taken When the DTC Sets....12074
Conditions for Clearing the MIL/DTC....12074
Diagnostic Aids....12074
DTC P1475 (Flash DTC 71) EXH #2 VSV Circuit Open/Short....12076
Circuit Description....12076
Action Taken When the DTC Sets....12076
Conditions for Clearing the MIL/DTC....12076
Diagnostic Aids....12076
DTC P1485 (Flash DTC 74) ITP (Intake Thorottle Position) Sensor Low Voltage....12078
Circuit Description....12078
Action Taken When the DTC Sets....12078
Conditions for Clearing the MIL/DTC....12078
Diagnostic Aids....12078
DTC P1486 (Flash DTC 74) ITP (Intake Throttle Position) Sensor High Voltage....12080
Circuit Description....12080
Action Taken When the DTC Sets....12080
Conditions for Clearing the MIL/DTC....12080
Diagnostic Aids....12080
DTC P1487 (Flash DTC 73) Intake Throttle System Circuit Open/Start....12082
Circuit Description....12082
Action Taken When the DTC Sets....12082
Conditions for Clearing the MIL/DTC....12082
Diagnostic Aids....12082
DTC P1488 (Flash DTC 72) Intake Throttle Motor Control Circuit Signal Gap....12084
Circuit Description....12084
Action Taken When the DTC Sets....12084
Conditions for Clearing the MIL/DTC....12084
Diagnostic Aids....12084
DTC P0502 (Flash DTC 24) VSS (Vehicle Speed Sensor) No Signal....12086
Circuit Description....12086
Action Taken When the DTC Sets....12086
Conditions for Clearing the MIL/DTC....12086
Test Description....12087
DTC P0510 (Flash DTC 75) Idle SW Malfunction, Open Circuit....12089
Circuit Description....12089
Action Taken When the DTC Sets....12089
Conditions for Clearing the MIL/DTC....12089
Diagnostic Aids....12089
DTC P1510 (Flash DTC 75) Idle SW Malfunction Short Circuit....12091
Circuit Description....12091
Action Taken When the DTC Sets....12091
Conditions for Clearing the MIL/DTC....12091
Diagnostic Aids....12091
DTC P0562 (Flash DTC 35) System Voltage Too Low....12093
Circuit Description....12093
Action Taken When the DTC Sets....12093
Conditions for Clearing the MIL/DTC....12093
Diagnostic Aids....12093
DTC P1562 (Flash DTC 35) System Voltage Too Low at Cranking....12094
Circuit Description....12094
Action Taken When the DTC Sets....12094
Conditions for Clearing the MIL/DTC....12094
Diagnostic Aids....12094
DTC P1587 (Flash DTC 25) Brake SW Malfunction....12095
Circuit Description....12095
Action Taken When the DTC Sets....12095
Conditions for Clearing the MIL/DTC....12095
Diagnostic Aids....12095
DTC P1588 (Flash DTC 25) Brake SW Malfunction....12097
Circuit Description....12097
Action Taken When the DTC Sets....12097
Conditions for Clearing the MIL/DTC....12097
Diagnostic Aids....12097
DTC P0601 (Flash DTC 55) ECM Checksum Error....12099
Action Taken When the DTC Sets....12099
Conditions for Clearing the MIL/DTC....12099
Diagnostic Aids....12099
DTC P0650 (Flash DTC 77) Check Engine Lamp Circuit Open/Short....12100
Circuit Description....12100
Action Taken When the DTC Sets....12100
Conditions for Clearing the MIL/DTC....12100
Diagnostic Aids....12100
DTC P0654 (Flash DTC 27) Tachometer Circuit Open/Short....12102
Circuit Description....12102
Action Taken When the DTC Sets....12102
Conditions for Clearing the MIL/DTC....12102
Diagnostic Aids....12102
DTC P1655 (Flash DTC 17) Thermo Relay Circuit Open/Short....12104
Circuit Description....12104
Action Taken When the DTC Sets....12104
Conditions for Clearing the MIL/DTC....12104
Diagnostic Aids....12104
DTC P1657 (Flash DTC 76) ECM Main Relay Circuit Open/Short....12106
Circuit Description....12106
Action Taken When the DTC Sets....12106
Conditions for Clearing the MIL/DTC....12106
Diagnostic Aids....12106
DTC P1589 (Flash DTC 47) Transmission SW Circuit Open/Short....12108
Circuit Description....12108
Action Taken When the DTC Sets....12108
Conditions for Clearing the MIL/DTC....12108
Diagnostic Aids....12108
Symptom Diagnosis....12110
Default Matrix Table....12133
On‐Vehicle Service Camshaft Position (CMP) Sensor....12135
Removal Procedure....12135
Inspection Procedure....12135
Installation Procedure....12135
Crankshaft Position (CKP) Sensor....12136
Removal Procedure....12136
Installation Procedure....12136
Engine Coolant Temperature (ECT) Sensor....12137
Removal Procedure....12137
Installation Procedure....12137
Intake Air Temperature (IAT) Sensor....12137
Removal Procedure....12137
Installation Procedure....12138
Manifold Absolute Pressure (MAP) Sensor....12138
Removal Procedure....12138
Installation Procedure....12139
Oil Temperature (OT) Sensor....12139
Removal Procedure....12139
Installation Procedure....12140
Malfunction Indicator Lamp (MIL)....12140
Removal and Installation Procedure....12140
Engine Control Module (ECM)....12140
Service Precaution....12140
Electrostatic Discharge (ESD) Damage....12140
Removal Procedure....12141
Installation Procedure....12142
EEPROM....12142
General Description....12142
Functional Check....12142
Intake Throttle Position (ITP) Sensor....12142
Removal Procedure....12142
Function Check....12143
Installation Procedure....12143
Vehicle Speed Sensor (VSS)....12144
Removal Procedure....12144
Inspection Procedure....12144
Installation Procedure....12144
Air Cleaner/Air Filter....12145
Removal Procedure....12145
Installation Procedure....12145
Accel Position (AP) Sensor....12145
Removal Procedure....12145
Installation Procedure....12146
Accelerator Pedal Replacement....12146
Removal Procedure....12146
Installation Procedure....12146
Fuel Filter Cap....12147
General Description....12147
Inspection Procedure....12147
Fuel Filter....12147
Removal and Installation Procedure....12147
Fuel Gauge Unit....12147
Removal Procedure....12147
Installation Procedure....12148
Fuel Injectors....12148
Removal and Installation Procedure....12148
Fuel Temperature Sensor....12148
Removal Procedure....12148
Installation Procedure....12149
Rail Pressure (RP) Sensor....12150
Removal Procedure....12150
Installation Procedure....12150
Fuel Tank....12150
Removal Procedure....12150
Throttle Body (TB)....12151
Removal Procedure....12151
Installation Procedure....12151
Air Conditioning (A/C) Relay....12151
Removal Procedure....12151
Installation Procedure....12151
Exhaust Gas Recirculation (EGR) Vacuum Switch Valve (VSV)....12151
Removal Procedure....12151
Installation Procedure....12152
Electronic Vacuum Regurating Valve (EVRV)....12153
Removal Procedure....12153
Installation Procedure....12154
Wiring and Connectors....12154
Wiring Harness Service....12154
Connectors and Terminals....12154
Wire Harness Repair: Twisted Shielded Cable....12154
Removal Procedure....12154
Installation Procedure....12155
Twisted Leads....12155
Removal Procedure....12155
Installation Procedure....12156
Weather-Pack Connector....12157
Tools Required....12157
Removal Procedure....12157
Installation Procedure....12157
Com-Pack III....12158
General Information....12158
Metri-Pack....12158
Tools Required....12158
Removal Procedure....12158
Installation Procedure....12158
General Description (ECM and Sensors)....12159
57X Reference ECM Input....12159
A/C Request Signal....12159
Crankshaft Position (CKP) Sensor....12159
Camshaft Position (CMP) Sensor and Signal....12159
Engine Coolant Temperature (ECT) Sensor....12159
Electrically Erasable Programmable Read Only Memory (EEPROM)....12159
Intake Air Temperature (IAT) Sensor....12159
Manifold Absolute Pressure (MAP) Sensor....12160
Engine Control Module (ECM)....12160
ECM Function....12160
ECM Components....12160
ECM Voltage Description....12160
ECM Input/Outputs....12160
ECM Service Precautions....12161
Intake Throttle Position (ITP) Sensor....12161
Transmission Range Switch....12161
Accelerator Position Sensor (AP)....12161
Aftermarket Electrical and Vacuum Equipment....12161
Electrostatic Discharge Damage....12161
General Description (Air Induction)....12162
Air Induction System....12162
General Description (Fuel Metering)....12162
Deceleration Mode....12162
Fuel Injector....12162
Fuel Metering System Components....12162
A/C Clutch Diagnosis....12162
A/C Request Signal....12162
General Description Exhaust Gas Recirculation (EGR) System....12162
EGR Purpose....12162
Fuse and Relay Panel (Underhood Electrical Center) RHD....12163
Fuse and Relay Panel (Underhood Electrical Center) LHD....12164
6F ENGINE EXHAUST....12165
GENERAL DESCRIPTION....12166
HANGERS....12166
GASKET....12166
ON-VEHICLE SERVICE....12167
FRONT EXHAUST PIPE....12167
CENTER EXHAUST PIPE....12169
EXHAUST SILENCER....12170
REAR EXHAUST PIPE....12171
6G ENGINE LUBRICATION....12173
GENERAL DESCRIPTION....12174
LUBRICATION CHART....12174
OIL FLOW....12175
OIL PUMP SPECIFICATIONS....12175
OIL FILTER SPECIFICATIONS....12175
SUB OIL FILTER SPECIFICATIONS....12176
OIL PUMP....12177
OIL COOLER ASSEMBLY....12178
OIL COOLER SPECIFICATIONS....12178
OIL FILTER....12178
SUB OIL FILTER....12178
6H ENGINE SPEED CONTROL....12179
GENERAL DESCRIPTION....12180
ACCELERATOR PEDAL....12181
6J INDUCTION....12183
GENERAL DESCRIPTION....12184
AIR CLEANER....12185
TURBOCHARGER....12186
INTERCOOLER....12191
INTAKE THROTTLE VALVE....12192
INTAKE MANIFOLD....12193
MAIN DATA AND SPECIFICATIONS....12194
Sec.7 TRANSMISSION....12199
7A AUTOMATIC TRANSMISSION (4L30‐E, 8bit Type)....12199
Service Precaution....12201
Construction....12201
Range Reference Chart....12202
Normal Operation Of 2000 4L30‐E Transmission....12203
Diagnosis....12203
Driver Information....12203
General Diagnosis Procedure....12206
Preliminary Inspection Chart....12207
Checking Transmission Fluid Level and Condition....12208
Test Driving....12209
Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart....12210
Mechanical / Hydraulic Diagnosis Symptoms Index....12211
Stall Test....12221
Line Pressure Test....12221
Shift Speed Chart (V6 3.2L 6VD1 Model)....12222
Shift Speed Chart (V6 3.5L 6VE1 Model)....12224
Lockup Speed Chart (V6 3.2L 6VD1 Model)....12226
Lockup Speed Chart (V6 3.5L 6VE1 Model)....12226
Changing Transmission Fluid....12227
Selector Lever....12227
Inspection....12227
Removal....12228
Installation....12228
Mode Switch....12229
Removal....12229
Installation....12229
Transmission (With Transfer Case)....12231
Transmission And Associated Parts....12231
Removal....12231
Installation....12233
Solenoid (Main Case Valve Body)....12237
Removal....12237
Installation....12237
Solenoid (Adapter Case Valve Body)....12238
Removal....12238
Installation....12238
Valve Body Assembly (Main Case)....12239
Removal....12239
Installation....12239
Valve Body Assembly (Adapter Case)....12241
Removal....12241
Installation....12241
Powertrain Control Module (PCM)....12241
Removal....12241
Installation....12241
Speed Sensor (Extension Housing)....12242
Removal....12242
Installation....12242
Transmission Oil Temperature Sensor (Adapter Case)....12242
Removal....12242
Installation....12243
Front Oil Seal (Converter Housing)....12243
Removal....12243
Installation....12243
Rear Oil Seal (Extension Housing)....12244
Removal....12244
Installation....12244
Transmission (4L30‐E)....12244
Disassembly....12244
Reassembly....12248
Converter Housing And Oil Pump Assembly....12258
Disassembled View....12258
Disassembly....12258
Inspection And Repair....12258
Reassembly....12258
Oil Pump....12259
Disassembled View....12259
Disassembly....12259
Inspection And Repair....12259
Reassembly....12259
Main Case Valve Body....12260
Disassembled View....12260
Disassembly....12260
Inspection And Repair....12261
Reassembly....12261
Adapter Case Valve Body....12262
Disassembled View....12262
Disassembly....12262
Inspection And Repair....12262
Reassembly....12262
Third Clutch And Sprag Unit....12263
Disassembled View....12263
Disassembly....12263
Inspection And Repair....12264
Reassembly....12264
Third Clutch....12265
Disassembled View....12265
Disassemble....12265
Inspection And Repair....12265
Reassembly....12265
Sprag Unit....12267
Disassembled View....12267
Disassembly....12267
Inspection And Repair....12267
Reassembly....12267
Second Clutch....12268
Disassembled View....12268
Disassembly....12268
Inspection And Repair....12269
Reassembly....12269
3–4 Accumulator Piston....12270
Disassembled View....12270
Disassembly....12270
Inspection And Repair....12271
Reassembly....12271
Reverse Clutch Piston And Center Support....12272
Disassembled View....12272
Disassembly....12273
Inspection And Repair....12273
Reassembly....12273
Overrun Clutch And Turbine Shaft....12274
Disassembled View....12274
Disassembly....12275
Inspection And Repair....12275
Reassembly....12275
Main Data And Specification....12277
Special Tools....12281
4L30–E Parts List....12284
7A AUTOMATIC TRANSMISSION (4L30‐E, 32bit Type)....12291
Service Precaution....12293
Construction....12293
Range Reference Chart....12294
Normal Operation Of 2002 4L30‐E Transmission....12295
Diagnosis....12295
Driver Information....12295
General Diagnosis Procedure....12298
Preliminary Inspection Chart....12299
Checking Transmission Fluid Level and Condition....12300
Test Driving....12301
Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart....12302
Mechanical / Hydraulic Diagnosis Symptoms Index....12303
Stall Test....12313
Line Pressure Test....12313
Shift Speed Chart....12314
Lockup Speed Chart....12316
Changing Transmission Fluid....12317
Selector Lever....12317
Inspection....12317
Removal....12317
Installation....12318
Mode Switch....12319
Removal....12319
Installation....12319
Transmission (With Transfer Case)....12321
Transmission And Associated Parts....12321
Removal....12322
Installation....12324
Solenoid (Main Case Valve Body)....12329
Removal....12329
Installation....12329
Solenoid (Adapter Case Valve Body)....12330
Removal....12330
Installation....12330
Valve Body Assembly (Main Case)....12331
Removal....12331
Installation....12331
Valve Body Assembly (Adapter Case)....12332
Removal....12332
Installation....12332
Powertrain Control Module (PCM)....12332
Removal....12332
Installation....12332
Speed Sensor (Extension Housing)....12333
Removal....12333
Installation....12333
Transmission Oil Temperature Sensor (Main Case)....12334
Removal....12334
Installation....12334
Oil Seal (Converter Housing)....12335
Removal....12335
Installation....12335
Rear Oil Seal (Extension Housing)....12335
Removal....12335
Installation....12335
Transmission (4L30‐E)....12336
Disassembly....12336
Reassembly....12340
Converter Housing And Oil Pump Assembly....12350
Disassembled View....12350
Disassembly....12350
Inspection And Repair....12350
Reassembly....12350
Oil Pump....12351
Disassembled View....12351
Disassembly....12351
Inspection And Repair....12352
Reassembly....12352
Main Case Valve Body....12353
Disassembled View....12353
Disassembly....12353
Inspection And Repair....12354
Reassembly....12354
Adapter Case Valve Body....12355
Disassembled View....12355
Disassembly....12355
Inspection And Repair....12355
Reassembly....12355
Third Clutch And Sprag Unit....12357
Disassembled View....12357
Disassembly....12357
Inspection And Repair....12357
Reassembly....12358
Third Clutch....12359
Disassembled View....12359
Disassemble....12359
Inspection And Repair....12359
Reassembly....12359
Sprag Unit....12361
Disassembled View....12361
Disassembly....12361
Inspection And Repair....12361
Reassembly....12361
Second Clutch....12362
Disassembled View....12362
Disassembly....12362
Inspection And Repair....12363
Reassembly....12363
3‐4 Accumulator Piston....12364
Disassembled View....12364
Disassembly....12364
Inspection And Repair....12365
Reassembly....12365
Reverse Clutch Piston And Center Support....12366
Disassembled View....12366
Disassembly....12367
Inspection And Repair....12367
Reassembly....12367
Overrun Clutch And Turbine Shaft....12368
Disassembled View....12368
Disassembly....12369
Inspection And Repair....12369
Reassembly....12369
Main Data And Specification....12371
General Specifications....12371
Torque Specifications....12372
Special Tools....12375
4L30‐E Parts List....12378
7A AUTOMATIC TRANSMISSION (AW30-40LE, Semi Type)....12386
GENERAL DESCRIPTION....12388
CONSTRUCTION....12388
ELECTRONIC CONTROL COMPONENTS....12389
TRANSMISSION CONTROL MODULE (TCM)....12390
CONTROL SYSTEM DIAGRAM....12391
CONTROL AND FUNCTIONS....12392
MAJOR INPUT/OUTPUT COMPONENTS....12394
LOCATION OF CLUTCH, BRAKE, ONE-WAY CLUTCH AND SOLENOID....12395
OPERATION OF CLUTCH, BRAKE AND ONE-WAY CLUTCH....12396
SPEED CHANGE AND LOCK-UP PATTERN....12396
OVERDRIVE AND LOCK-UP OPERATING CONDITIONS....12397
DIAGNOSIS....12398
BASIC TROUBLESHOOTING....12398
SELF-DIAGNOSIS....12399
DIAGNOSIS WITH TECH2....12402
TECH2 CONNECTION....12403
TECH2 OPERATING FLOW CHART (START UP)....12404
TRANSMISSION DATA....12406
TCC DATA....12407
INTERMITTENT CONDITIONS....12408
IDENTIFICATION OF TRANSMISSION CONTROL MODULE (TCM)....12409
DIAGNOSTIC TROUBLE CODES (DTC) CHECK....12410
WIRING DIAGRAM....12437
CONNECTOR LIST....12439
TROUBLESHOOTING CHART....12441
MANUAL SHIFTING TEST....12447
STALL TEST....12448
TIME LAG TEST....12449
HYDRAULIC TEST....12450
ROAD TEST....12451
SHIFT POINT CHART AND LOCK-UP POINT CHART....12454
TCM VOLTAGE CHECK....12456
TCM STANDARD VOLTAGE....12457
ON-VEHICLE SERVICE....12460
TRANSIMISSION FLUID LEVEL AND CONDITION....12460
ATF REPLACEMENT....12460
NEUTRAL START SWITCH INSPECTION....12461
BRAKE SIGNAL INSPECTION....12462
VEHICLE SPEED SENSOR INSPECTION....12462
INPUT AND OUTPUT REVOLUTION SENSOR INSPECTION....12462
PATTERN SELECT SWITCH INSPECTION....12463
OVERDRIVE OFF SWITCH INSPECTION....12463
SOLENOID INSPECTION....12463
THROTTLE POSITION SENSOR INSPECTION....12464
ATF TEMPERATURE SENSOR INSPECTION....12464
SELECTOR LEVER....12465
TRANSMISSION CONTROL MODULE (TCM)....12468
SHIFT SOLENOID AND LOCK-UP SOLENOID....12468
VALVE BODY ASSEMBLY AND PRESSERE CONTOROL SOLENOID....12469
TRANSMISSION REMOVAL AND INSTALLATION....12471
UNIT REPAIR....12476
DISASSEMBLY OF MAJOR COMPONENTS....12476
DISASSEMBLY, INSPECTION AND REASSEMBLY OF MINOR COMPONENTS....12492
OIL PUMP....12493
OD PLANETARY GEAR AND OD DIRECT CLUTCH ASSEMBLY (C-0)....12499
OD SUPPORT ASSEMBLY....12511
DIRECT CLUTCH ASSEMBLY (C-2)....12518
FORWARD CLUTCH ASSEMBLY (C-1)....12526
FRONT PLANETARY GEAR....12535
PLANETARY SUN GEAR AND NO.1 ONE–WAY CLUTCH....12538
SECOND BRAKE ASSEMBLY (B–2)....12543
REAR PLANETARY GEAR ASSEMBLY AND OUTPUT SHAFT....12548
FIRST AND REVERSE BRAKE (B–3)....12556
TRANSMISSION CASE....12562
TORQUE CONVERTER....12566
REASSEMBLY OF MAJOR COMPONENTS....12567
MAIN DATA AND SPECIFICATIONS....12592
GENERAL SPECIFICATIONS....12592
TORQUE SPECIFICATIONS....12593
SPECIAL TOOLS....12596
7A1 TRANSMISSION CONTROL SYSTEM (4L30‐E, 8bit Type)....12598
Service Precaution....12599
General Description....12599
Electronic Control Diagram....12600
Powertrain Control Module (PCM)....12601
Control System Diagram....12602
Shift Control....12603
Band Apply Control....12603
Torque Converter Clutch Control....12603
Line Pressure Control....12603
On–Board Diagnostic System....12603
Fail Safe Mechanism....12603
Torque Management Control....12603
ATF Warning Control....12603
ABS Control (If equipped)....12603
Shift Mode Control....12604
Gear Shift Control....12605
Winter Drive Mode....12606
Backup Mode....12606
Functions of Input / Output Components....12607
Diagnosis....12608
Electronic Diagnosis....12608
Check Trans Indicator....12608
Diagnostic Check....12608
“Check Trans” Check....12609
Tech2 OBD II Connection....12610
F0: Transmission Data....12615
F1: PC Solenoid Data....12616
OBD II Diagnostic Management System....12617
16 – Terminal Data Link Connector (DLC)....12618
Malfunction Indicator Lamp (MIL)....12619
Types Of Diagnostic Trouble Codes (DTCs)....12619
Clear DTC....12619
DTC Check....12620
PCM Precaution....12620
Information On PCM....12620
Intermittent Conditions....12620
Transmission And PCM Identification....12621
Isuzu Trooper....12622
Diagnostic Trouble Code (DTC) Identification....12623
DTC P0218 Transmission Fluid Over Temperature....12624
DTC P0560 System Voltage Malfunction....12626
DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position....12629
DTC P0706 Transmission Range Switch (Mode Switch) Performance....12632
DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input....12635
DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input....12638
DTC P0719 TCC Brake Switch Circuit High (Stuck On)....12641
DTC P0722 Transmission Output Speed Sensor (OSS) Low Input....12644
DTC P0723 Transmission Output Speed Sensor (OSS) Intermittent....12647
DTC P0730 Transmission Incorrect Gear Ratio....12650
DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical....12653
DTC P0753 Shift Solenoid A Electrical....12655
DTC P0758 Shift Solenoid B Electrical....12658
DTC P1790 ROM Transmission Side Bad Check Sum....12662
DTC P1792 EEPROM Transmission Side Bad Check Sum....12663
DTC P1835 Kickdown Switch Always On....12664
DTC P1850 Brake Band Apply Solenoid Malfunction....12666
DTC P1860 TCC Solenoid Electrical....12670
Transmission Fluid Temperature (TFT) Sensor Specifications....12673
7A1 TRANSMISSION CONTROL SYSTEM (4L30‐E, 32bit Type)....12674
Service Precaution....12675
General Description....12675
Electronic Control Diagram....12676
Powertrain Control Module (PCM)....12677
Control System Diagram....12678
Shift Control....12679
Band Apply Control....12679
Torque Converter Clutch Control (Electronically Controlled Capacity Clutch = ECCC)....12679
Line Pressure Control....12679
On–Board Diagnostic System....12679
Fail Safe Mechanism....12679
Torque Management Control....12679
ATF Warning Control....12679
ABS Control....12679
Reverse Lock Out Control....12679
Downhill Control....12679
Uphill Control....12679
Shift Mode Control....12680
Gear Shift Control....12681
Winter Drive Mode....12682
Backup Mode....12682
Functions of Input / Output Components....12683
Diagnosis....12684
Electronic Diagnosis....12684
Check Trans Indicator....12684
Diagnostic Check....12684
“Check Trans” Check....12685
Tech 2 OBD II Connection....12687
Transmission Data....12692
OBD II Diagnostic Management System....12693
16 ‐ Terminal Data Link Connector (DLC)....12694
Malfunction Indicator Lamp (MIL)....12695
DTC Types....12695
Clear DTC....12696
DTC Check....12696
PCM Precaution....12696
Information On PCM....12697
Intermittent Conditions....12697
Transmission And PCM Identification....12698
Isuzu UBS....12698
Diagnostic Trouble Code (DTC) Identification....12699
DTC P0218 Transmission Fluid Over Temperature....12700
DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position....12702
DTC P0706 Transmission Range Switch (Mode Switch) Performance....12706
DTC P0711 Transmission Fluid Temperature (TFT) Sensor Performance....12710
DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input....12713
DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input....12716
DTC P0719 Brake Switch Circuit Low (Stuck On)....12719
DTC P0722 Automatic Transmission Output Speed Sensor (OSS) Low Input....12722
DTC P0723 Automatic Transmission Output Speed Sensor (OSS) Intermittent....12725
DTC P0724 Brake Switch Circuit High (Stuck Off)....12728
DTC P0730 Gear Error Without Input Speed....12730
DTC P0742 Torque Converter Clutch (TCC) System Stuck On....12733
DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical....12735
DTC P0751 Shift Solenoid A Performance (Stuck OFF)....12737
DTC P0752 Shift Solenoid A Performance (Stuck ON)....12739
DTC P0753 Shift Solenoid A Electrical....12741
DTC P0756 Shift Solenoid B Performance (Stuck OFF)....12745
DTC P0757 Shift Solenoid B Performance (Stuck ON)....12747
DTC P0758 Shift Solenoid B Electrical....12749
DTC P1850 Brake Band Apply Solenoid Malfunction....12754
DTC P1860 TCC PWM Solenoid Electrical....12759
Circuit Description....12759
DTC P1870 Transmission Component Slipping (TCC Stuck OFF)....12762
Circuit Diagram (LHD)....12764
Circuit Diagram (RHD)....12766
Harness Connector Faces (LHD)....12768
Harness Connector Faces (RHD)....12770
Transmission Fluid Temperature (TFT) Sensor Specifications....12772
7B MANUAL TRANSMISSION (AR-5)....12773
Service Precaution....12773
General Description....12774
Diagnosis....12776
Manual Transmission Assembly....12777
Transmission and Associated Parts....12777
Removal....12778
Installation....12783
Rear Oil Seal (Transfer Adapter)....12789
Removal....12789
Installation....12789
Transmission (AR-5)....12790
Disassembled View....12790
Disassembly....12793
Inspection....12811
Reassembly....12813
Main Data and Specifications....12840
General Specifications....12840
Torque Specifications....12841
Special Tools....12844
7B MANUAL TRANSMISSION (MUA)....12846
4X2 MODEL TRANSMISSION....12847
Main Data and Specifications....12847
General Description....12848
Torque Specifications....12849
Recommended Liquid Gasket....12851
Removal and Installation....12852
Disassembly....12861
Inspection and Repair....12871
Reassembly....12876
4X4 MODEL TRANSMISSION....12891
Main Data and Specifications....12891
General Description....12892
Torque Specifications....12893
Recommended Liquid Gasket....12895
Removal and Installation....12896
Disassembly....12906
Inspection and Repair....12926
Reassembly....12932
Troubleshooting....12957
7C CLUTCH....12965
Service Precaution....12965
General Description....12966
Diagnosis....12972
Clutch Assembly....12973
Clutch Assembly and Associated Parts....12973
Removal....12973
Inspection and Repair....12974
Installation....12979
Clutch Control....12981
Clutch Control Parts....12981
Removal....12982
Inspection and Repair....12982
Installation....12983
Adjustment....12983
Master Cylinder....12986
Disassembled View....12986
Disassembly....12987
Inspection and Repair....12987
Reassembly....12987
Slave Cylinder....12988
Disassembled View....12988
Disassembly....12988
Inspection and Repair....12988
Reassembly....12989
Damper Cylinder....12990
Disassembled View....12990
Disassembly....12990
Inspection and Repair....12990
Reassembly....12990
Main Data and Specifications....12991
General Specifications....12991
Torque Specifications....12991
Special Tools....12994
Sec.8 BODY AND ACCESSORIES....12995
8A LIGHTING SYSTEM....12995
Service Precaution....12996
Headlight Bulb....12997
Removal....12997
Installation....12997
Headlight....12998
Headlight and Associated Parts....12998
Removal....12998
Installation....12998
Headlight Adjustment....12998
Fog Light Bulb....12999
Removal....12999
Installation....12999
Fog Light Assembly....13000
Removal....13000
Installation....13000
Fog Light Adjustment....13000
Clarence Light Bulb....13000
Removal....13000
Installation....13000
Rear Fog Light Bulb (RHD)....13001
Removal....13001
Installation....13001
Taillight Bulb (Body)....13001
Removal....13001
Installation....13001
Taillight Bulb (Bumper)....13002
Removal....13002
Installation....13002
License Plate Light Bulb (Body)....13002
Removal....13002
Installation....13002
License Plate Light Bulb (Bumper)....13003
Removal....13003
Installation....13003
Stoplight Bulb....13003
Removal and Installation....13003
High Mount Stoplight....13004
Removal....13004
Installation....13004
Front Turn Signal Light Bulb....13004
Removal....13004
Installation....13004
Side Turn Signal Light Bulb....13005
Removal....13005
Installation....13005
Rear Turn Signal Light Bulb....13005
Removal....13005
Installation....13005
Backup Light Bulb....13006
Removal....13006
Installation....13006
Dome Light Bulb....13006
Removal....13006
Installation....13006
Luggage Room Light Bulb....13007
Removal....13007
Installation....13007
Courtesy Light Bulb....13007
Removal....13007
Installation....13007
Map Light Switch/Bulb....13008
Removal....13008
Installation....13008
Cigarette Lighter Illumination Bulb....13008
Removal....13008
Installation....13008
Ashtray Illumination Bulb....13009
Removal....13009
Installation....13009
Glove Box Illumination Bulb....13009
Removal....13009
Installation....13009
Vanity Mirror Illumination Bulb....13010
Removal....13010
Installation....13010
Starter Switch....13011
Removal....13011
Installation....13011
Lighting Switch (Combination Switch)....13012
Removal....13012
Installation....13012
Fog Light Switch....13013
Removal....13013
Installation....13013
Stoplight Switch (W/O Cruise Control)....13014
Removal....13014
Installation....13014
Brake Switch (W/Cruise Control)....13015
Removal....13015
Installation....13015
Turn Signal Switch (Combination Switch)....13015
Removal and Installation....13015
Hazard Warning Switch....13016
Removal....13016
Installation....13016
Tailgate Switch....13017
Removal....13017
Installation....13017
Door Switch....13017
Removal....13017
Installation....13017
Rear Defogger Switch....13018
Removal....13018
Installation....13018
Seat Heater Switch....13019
Removal....13019
Installation....13019
Key Remind Switch (Starter Switch)....13019
Removal and Installation....13019
Illumination Controller....13020
Removal....13020
Installation....13020
Power/Winter Switch....13021
Removal....13021
Installation....13021
Main Data and Specifications....13022
8B WIPER / WASHER SYSTEM....13025
Service Precaution....13026
Windshield Wiper/Washer System....13026
General Description....13026
Windshield Wiper And Washer Switch....13026
Removal and Installation....13026
Windshield Wiper Motor....13026
Removal....13026
Installation....13026
Windshield Washer Motor....13027
Removal....13027
Installation....13027
Windshield Wiper Linkage....13028
Windshield Wiper Linkage and Associated Parts....13028
Removal....13028
Installation....13028
Windshield Wiper Arm/Blade....13029
Removal....13029
Installation....13029
Windshield Wiper Blade Rubber....13030
Removal....13030
Installation....13030
Rear Wiper/Washer System....13031
General Description....13031
Rear Wiper and Washer Switch....13031
Removal....13031
Installation....13031
Rear Wiper Motor....13032
Removal....13032
Installation....13032
Alarm & Relay Control Unit....13033
Removal....13033
Installation....13033
Rear Washer Motor....13033
Removal....13033
Installation....13033
Rear Wiper Arm/Blade....13034
Removal....13034
Installation....13034
Rear Washer Nozzle....13034
Removal....13034
Installation....13034
Rear Washer Nozzle Angle Adjustment....13034
Rear Wiper Blade Rubber....13035
Removal and Installation....13035
Headlight Wiper/Washer....13035
General Description....13035
Headlight Wiper and Washer Switch....13036
Removal....13036
Installation....13036
Headlight Wiper Arm & Blade....13037
Removal....13037
Installation....13037
Headlight Wiper Motor....13037
Removal....13037
Installation....13037
Headlight Washer Motor....13038
Removal and Installation....13038
Main Data and Specifications....13038
8C ENTERTAINMENT....13039
Service Precaution....13039
Cigarette Lighter....13040
General Description....13040
Removal....13040
Installation....13040
Digital Clock....13041
Removal....13041
Installation....13041
Rod Type Antenna....13042
Removal....13042
Installation....13042
Auto Antenna....13043
General Description....13043
Removal....13043
Installation....13043
Antenna Rod....13044
Removal....13044
Installation....13044
Radio....13045
Removal....13045
Installation....13045
Front Speaker....13046
Removal....13046
Installation....13046
Rear Speaker....13047
Removal....13047
Installation....13047
8D WIRING SYSTEM....13049
Service Precaution....13051
General Description....13052
Notes for Working on Electrical Items....13052
Symbols and Abbreviations....13058
Parts for Electrical Circuit....13060
Reading the Circuit Diagram....13069
Main Data and Specifications....13072
Fuse, Fusible Link and Circuit Breaker Location....13072
Relay Location....13075
Diode Location....13078
Grounding Point....13079
Cable Harness Routing....13091
Fuse Block Circuit....13099
Circuit Diagram....13100
Start and Charging....13113
General Description....13113
Circuit Diagram....13114
Parts Location....13116
Powertrain Control Module (PCM)....13126
General Description....13126
Circuit Diagram....13127
Parts Location....13139
QOS-III (4JG2)....13157
General Description....13157
Circuit Diagram....13158
Parts Location....13160
QOS and EGR System (4JG2)....13164
General Description....13164
Circuit Diagram....13165
Parts Location....13168
Headlight and Fog Light....13173
General Description....13173
Circuit Diagram....13174
Parts Location....13176
Diagnosis....13180
Rear Fog Light....13196
General Description....13196
Circuit Diagram....13197
Parts Location....13200
Diagnosis....13201
Headlight Leveling....13203
General Description....13203
Circuit Diagram....13204
Parts Location....13205
Diagnosis....13206
Clearance Light, Taillight and License Plate Light....13209
General Description....13209
Circuit Diagram....13210
Parts Location....13213
Diagnosis....13218
Interior Illumination Light....13230
General Description....13230
Circuit Diagram....13231
Parts Location....13235
Diagnosis....13242
Turn Signal Light and Hazard Warning Light....13243
General Description....13243
Circuit Diagram....13244
Parts Location....13247
Parts Location....13251
Stoplight....13258
General Description....13258
Circuit Diagram....13259
Parts Location....13262
DIAGNOSIS....13266
Backup Light....13270
General Description....13270
Circuit Diagram....13271
Parts Location....13273
Diagnosis....13277
Horn....13280
General Description....13280
Circuit Diagram....13281
Parts Location....13282
Diagnosis....13285
Dome Light, Luggage Room Light, Courtesy Light and Map Light....13287
General Description....13287
Circuit Diagram....13288
Parts Location....13290
Power Door Lock....13294
General Description....13294
Circuit Diagram....13295
Parts Location....13300
Diagnosis....13306
Power Window....13311
General Description....13311
Circuit Diagram....13312
Parts Location....13313
Diagnosis....13316
Cruise Control....13322
General Description....13322
Circuit Diagram....13323
Parts Location....13325
Diagnosis....13329
Anti-lock Brake System (ABS)....13334
General Description....13334
Circuit Diagram....13335
Parts Location....13341
A/T Shift Lock....13348
General Description....13348
Circuit Diagram....13349
Parts Location....13350
Windshield Wiper/Washer....13353
General Description....13353
Circuit Diagram....13354
Parts Location....13355
Diagnosis....13358
Rear Wiper/Washer....13366
General Description....13366
Circuit Diagram....13367
Parts Location....13369
Diagnosis....13373
Headlight Wiper/Washer....13379
General Description....13379
Circuit Diagram....13380
Parts Location....13382
Diagnosis....13386
Rear Defogger....13392
General Description....13392
Circuit Diagram....13393
Parts Location....13394
Diagnosis....13397
Audio....13400
General Description....13400
Circuit Diagram....13401
Parts Location....13405
Cigarette Lighter and Digital Clock....13409
General Description....13409
Circuit Diagram....13410
Parts Location....13411
Power Door Mirror....13414
General Description....13414
Circuit Diagram....13415
Parts Location....13418
Diagnosis....13423
Anti-Theft System with Keyless Entry....13430
Circuit Diagram....13431
Parts Location....13442
Diagnosis....13449
Meter and Warning/Indicator Light....13462
General Description....13462
Circuit Diagram....13463
Parts Location....13481
Diagnosis....13497
A/T Shift Indicator....13516
General Description....13516
Circuit Diagram....13517
Parts Location....13519
Heater and Air Conditioning....13523
General Description....13523
Circuit Diagram....13524
Parts Location....13526
Sun Roof....13536
General Description....13536
Circuit Diagram....13537
Parts Location....13538
Diagnosis....13541
Seat Heater....13545
General Description....13545
Circuit Diagram....13546
Parts Location....13547
Diagnosis....13550
Power Seat....13552
General Description....13552
Circuit Diagram....13553
Parts Location....13555
Diagnosis....13559
Shift On The Fly System....13565
Circuit Diagram....13566
Parts Location....13568
Torque on Demand (T.O.D.)....13590
Circuit Diagram....13591
Parts Location....13594
Supplemental Restraint System (SRS) – Air Bag....13595
General Description....13595
Circuit Diagram....13596
Parts Location....13600
Connector List....13602
8E METER AND GAUGE....13637
Service Precaution....13637
General Description....13637
Meter Assembly....13638
General Description....13638
Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination Lights....13638
Table for Meter/Gauge Connector Terminal Connections....13644
Removal....13650
Installation....13650
Warning Light Bulb, Indicator Light Bulb, Illumination Light Bulb, A/T Indicator Light Bulb....13650
Removal....13650
Installation....13650
Vehicle Speed Sensor....13651
Removal....13651
Installation....13651
Fuel Tank Unit....13651
Removal....13651
Installation....13651
Multi Meter....13652
Removal....13652
Installation....13652
Ambient Sensor....13652
Removal....13652
Installation....13652
Main Data and Specifications....13653
8F BODY STRUCTURE....13655
Service Precaution....13657
Frame....13657
General Description....13657
Frame Dimensions (L W B)....13658
Frame Dimensions (S W B)....13659
General Description....13660
Front Bumper....13660
Parts Location....13660
Removal....13661
Installation....13661
Front Bumper Slider Bracket....13661
Removal....13661
Installation....13661
Rear Bumper....13662
Parts Location....13662
Removal....13662
Installation....13663
Parts Location (W/Rear Combination Light and License Light)....13664
Removal....13664
Installation....13665
Rear Bumper Slider....13666
Removal....13666
Installation....13666
General Description....13667
Cowl Cover....13667
Parts Location....13667
Removal....13667
Installation....13668
Engine Hood....13668
Removal....13668
Installation....13668
Air Bulge....13669
Parts Location....13669
Removal....13669
Installation....13669
Engine Hood Hinge....13670
Parts Location....13670
Removal....13670
Installation....13670
Engine Hood Lock....13671
Parts Location....13671
Removal....13671
Installation....13672
Radiator Grille And Front End Lower Panel....13672
Parts Location....13672
Removal....13672
Installation....13673
Front Fender Panel....13674
Parts Location....13674
Removal....13674
Installation....13675
Body Mounting....13676
Parts Location....13676
Removal (No.1 – No. 2)....13676
Removal (No. 3 — No. 6)....13677
Installation....13678
General Description....13679
Body Dimension....13680
Instrument Panel Assembly....13700
Parts Location....13700
Removal....13701
Installation....13705
Cross Beam Assembly....13706
Parts Location....13706
Removal....13706
Installation....13707
Front Door Assembly....13708
Parts Location....13708
Removal....13708
Installation....13708
Rear Door Assembly....13709
Parts Location....13709
Removal....13709
Installation....13710
Door Strikers....13710
Adjustment....13710
Door Check Arm Assembly (Front & Rear)....13711
Parts Location....13711
Removal....13711
Installation....13712
Front Window Regulator, Glass And Glass Run....13712
Parts Location....13712
Removal....13712
Installation....13714
Rear Window Regulator And Glass....13715
Parts Location....13715
Removal....13715
Installation....13716
Rear Door Fixed Glass And Glass Run....13717
Parts Location....13717
Removal....13717
Installation....13718
Front Door Sash Moulding....13719
Parts Location....13719
Removal....13719
Installation....13719
Rear Door Moulding....13720
Parts Location....13720
Removal....13720
Installation....13720
Front Door Waist Seal....13721
Parts Location....13721
Removal....13721
Installation....13721
Rear Door Waist Seal....13722
Parts Location....13722
Removal and Installation....13722
Front Door Weatherstrip....13723
Parts Location....13723
Removal....13723
Installation....13724
Rear Door Weatherstrip....13725
Parts Location....13725
Removal and Installation....13725
Front Door Seal Finisher....13726
Parts Location....13726
Removal....13726
Installation....13726
Rear Door Seal Finisher....13727
Parts Location....13727
Removal....13727
Installation....13727
Tailgate Assembly (LH)....13728
Parts Location....13728
Removal....13728
Installation....13729
Tailgate Assembly (RH)....13730
Parts Location....13730
Removal....13730
Installation....13731
Tailgate Strikers....13732
Adjustment....13732
Tailgate Stopper Assembly....13732
Parts Location....13732
Removal....13732
Installation....13732
Tailgate Dove-Tail....13733
Parts Location....13733
Removal....13733
Installation....13733
Tailgate Dove-Tail Striker....13734
Adjustment....13734
Tailgate Frame Cover (LH)....13735
Parts Location....13735
Removal....13735
Installation....13735
Tailgate Frame Cover (RH)....13736
Removal....13736
Installation....13736
Tailgate Sash Trim Cover....13737
Parts Location....13737
Removal....13737
Installation....13737
Tailgate Outer Weatherstrip....13738
Parts Location....13738
Removal....13738
Installation....13738
Tailgate Center Weatherstrip....13739
Parts Location....13739
Removal....13739
Installation....13739
Tailgate Main Weatherstrip....13740
Parts Location....13740
Removal....13740
Installation....13740
Spare Tire Carrier....13741
Parts Location....13741
Removal....13741
Installation....13741
Headlining....13742
Parts Location....13742
Removal....13742
Installation....13743
Rear Air Deflector....13744
Parts Location....13744
Removal....13744
Installation....13744
Roof Moulding....13746
Parts Location....13746
Removal....13746
Installation....13747
Windshield....13748
Parts Location....13748
Removal....13748
Installation....13749
Rear Quarter Side Glass....13753
Parts Location....13753
Removal....13753
Installation....13754
Tailgate Glass....13756
Parts Location....13756
Removal....13756
Installation....13757
Main Data and Specifications....13758
Special Tools....13769
8G SEATS....13770
Service Precaution....13770
Front Seat Assembly....13771
Front Seat Assembly and Associated Parts....13771
Removal....13771
Installation....13772
Disassembled View (LWB)....13772
Disassembly....13773
Reassembly....13774
Disassembled View (SWB)....13775
Disassembly....13775
Reassembly....13777
Power Seat Assembly....13778
General Description....13778
Disassembled View....13778
Disassembly....13779
Reassembly....13781
Power Seat Switch....13781
Removal....13781
Installation....13781
Front Tilt Motor / Rear Tilt Motor / Slide Motor / Recliner Motor....13782
Parts Location....13782
Removal and Installation....13782
Seat Heater System....13783
General Description....13783
Seat Heater Switch Removal and Installation....13783
Heat Unit Parts Location....13783
Heat Unit Removal and Installation....13783
Rear Seat Assembly....13784
Rear Seat Assembly and Associated Parts....13784
Removal....13784
Installation....13784
Disassembled View (Split Type)....13785
Disassembly (Split Type)....13786
Reassembly (Split Type)....13787
Disassembled View (SWB)....13788
Disassembly....13788
Reassembly....13789
Disassembled View (Bench Type)....13790
Disassembly (Bench Type)....13791
Reassembly (Bench Type)....13792
Third Seat Assembly....13792
Parts Location....13792
Removal....13792
Installation....13793
Disassembled View....13793
Disassembly....13794
Reassembly....13794
Rear Seat Foot Rest....13794
Rear Seat Foot Rest and Associated Parts....13794
Removal....13795
Installation....13795
Main Data and Specifications....13795
8H SECURITY AND LOCKS....13797
Service Precaution....13798
Front Door Lock Assembly....13798
Front Door Lock Assembly and Associated Parts....13798
Removal....13798
Installation....13799
Front Outside Handle and Door Lock Cylinder....13800
Front Outside Handle, Door Lock Cylinder and Associated Parts....13800
Removal....13800
Installation....13801
Rear Door Lock Assembly....13803
Rear Door Lock Assembly and Associated Parts....13803
Removal....13803
Installation....13804
Rear Outside Handle....13805
Rear Outside Handle and Associated Parts....13805
Removal....13805
Installation....13806
Rear Door Inside Lock Knob Link....13806
Removal....13806
Installation....13806
Door Inside Lock Knob....13807
Removal....13807
Installation....13807
Door Inside Handle....13807
Removal and Installation....13807
Tailgate Lock Assembly (LH)....13808
Tailgate Lock Assembly (LH) and Associated Parts....13808
Removal....13808
Installation....13809
Tailgate Lock Assembly (RH)....13810
Tailgate Lock Assembly (RH) and Associated Parts....13810
Removal....13810
Installation....13811
Tailgate Inside Lock Knob....13811
Removal....13811
Installation....13811
Tailgate Inside Handle....13812
Parts Location....13812
Removal and Installation....13812
Tailgate Outside Handle and/or Tailgate Lock Cylinder....13813
Tailgate Outside Handle and/or Tailgate Lock Cylinder and Associated Parts....13813
Removal....13813
Installation....13814
Key....13815
Key Coding....13815
Key Styles....13815
Power Door Lock System....13816
General Description....13816
Front Door Lock Actuator Removal....13816
Front Door Lock Actuator Installation....13816
Rear Door Lock Actuator Removal....13816
Rear Door Lock Actuator Installation....13817
Tailgate Lock Actuator Removal....13817
Tailgate Lock Actuator Installation....13817
Anti-theft System....13818
General Description....13818
Anti-theft & Keyless Entry Control Unit Removal....13818
Anti-theft & Keyless Entry Control Unit Installation....13818
Anti-theft Indicator Removal....13818
Anti-theft Indicator Installation....13819
Anti-theft Horn Removal....13819
Anti-Theft Horn Installation....13819
Engine Hood Switch Removal....13819
Engine Hood Switch Installation....13819
Keyless Entry System....13820
ID Code Registration (Except South Africa)....13820
Anti‐theft & Keyless Entry Control Unit/Transmitter Replacement....13822
Programming With Tech 2 (For South Africa)....13823
Main Data and Specifications....13825
8I SUN ROOF/CONVERTIBLE TOP....13826
Service Precaution....13826
Sun Roof Glass....13827
Sun Roof Glass and Associated Parts....13827
Removal....13827
Installation....13828
Sun Roof Deflector....13829
Removal....13829
Installation....13829
Sunshade....13829
Disassembled View....13829
Removal....13830
Installation....13830
Sun Roof Frame Complete Assembly....13831
Sun Roof Frame Complete Assembly and Associated Parts....13831
Removal....13831
Installation....13832
Disassembled View....13832
Disassembly....13832
Reassembly....13833
Sun Roof Drain Hose (Front Side)....13834
Sun Roof Drain Hose (Front Side) and Associated Parts....13834
Removal....13834
Installation....13834
Sun Roof Drain Hose (Rear Side)....13835
Sun Roof Drain Hose (Rear Side) and Associated Parts....13835
Removal....13835
Installation....13835
Sun Roof Switch....13836
General Description....13836
Removal....13836
Installation....13836
Sun Roof Motor....13837
Removal....13837
Installation....13837
Main Data and Specifications....13837
8J EXTERIOR / INTERIOR TRIM....13838
Service Precaution....13839
Dash Side Trim Panel....13840
Removal....13840
Installation....13840
Assist Grip....13840
Parts Location....13840
Removal and Installation....13840
Consoles....13841
Consoles and Associated Parts....13841
Removal....13841
Installation....13842
Front Door Trim Panel....13843
Front Door Trim Panel and Associated Parts....13843
Removal....13843
Installation....13846
Rear Door Trim Panel....13847
Rear Door Trim Panel and Associated Parts....13847
Removal....13847
Installation....13848
Door Mirror....13850
Door Mirror and Associated Parts....13850
Removal....13850
Installation....13850
Luggage Side and Quarter Upper Trim Cover (LWB)....13851
Luggage Side, Quarter Upper Trim Cover and Associated Parts....13851
Removal....13851
Installation....13853
Luggage Side and Quarter Upper Trim Cover (SWB)....13854
Luggage Side, Quarter Upper Trim Cover and Associated Parts....13854
Removal....13854
Installation....13856
Center Pillar and Roof Side Trim Cover (LWB)....13857
Center Pillar, Roof Side Trim Cover and Associated Parts....13857
Removal....13857
Installation....13858
Roof Side Trim Cover (SWB)....13859
Roof Side Trim Cover and Associated Parts....13859
Removal....13859
Installation....13859
Front Pillar Trim Cover....13860
Front Pillar Trim Cover and Associated Parts....13860
Removal....13860
Installation....13860
Center Pillar Assist Grip....13861
Parts Location....13861
Removal and Installation....13861
Assist Grip....13861
Parts Location....13861
Removal and Installation....13861
Fuel Filler Lid Opener Cable....13862
Fuel Filler Lid Opener Cable and Associated Parts....13862
Removal....13862
Installation....13863
Fuel Filler Door....13863
Parts Location....13863
Removal....13863
Installation....13863
Rocker Protector (Without Wheel Opening Extension)....13864
Rocker Protector (Without Wheel Opening Extension) and Associated Parts....13864
Removal....13864
Installation....13864
Wheel Opening Extension and Rocker Protector Assembly....13865
Wheel Opening Extension, Rocker Protector Assembly and Associated Parts....13865
Removal....13865
Installation....13866
Mud Flaps (With Wheel Opening Extension)....13868
Mud Flaps (With Wheel Opening Extension) and Associated Parts....13868
Removal....13868
Installation....13868
Ventilation Assembly....13869
Ventilation Assembly and Associated Parts....13869
Removal....13869
Installation....13869
Quarter Flipper Glass Assembly (SWB)....13870
Quarter Flipper Glass Assembly and Associated Parts....13870
Removal....13870
Installation....13870
Tailgate Trim Panel (LH)....13871
Tailgate Trim Panel (LH) and Associated Parts....13871
Removal....13871
Installation....13872
Tailgate Trim Panel (RH)....13873
Parts Location....13873
Removal....13873
Installation....13873
Luggage Floor Box....13874
Luggage Floor Box and Associated Parts....13874
Remove....13874
Installation....13874
Rope Hook Set....13874
Rope Hook Set and Associated Parts....13874
Removal....13874
Installation....13874
Power Door Mirror System....13875
General Description....13875
Door Mirror Switch Assembly (Control Switch, Folding Switch and Defogger Switch) Removal....13875
Installation....13875
Power Door Mirror....13875
General Description....13875
Removal and Installation....13875
Power Window System....13876
General Description....13876
Power Window Switch Removal and Installation....13876
Power Window Motor Removal and Installation....13877
Main Data and Specifications....13878
Sec.9 RESTRAINTS....13879
9A SEAT BELT SYSTEM....13879
Service Precaution....13879
Seat Belt....13880
Front Seat Belt and Associated Parts (Long Wheel Base)....13880
Removal....13880
Inspection....13880
Installation....13881
Front Seat Belt and Associated Parts (Short Wheel Base)....13882
Removal....13882
Inspection....13882
Installation....13883
Rear Seat Belt and Associated Parts (Long Wheel Base)....13884
Removal....13884
Inspection....13884
Installation....13885
Rear Seat Belt and Associated Parts (Short Wheel Base)....13886
Removal....13886
Inspection....13887
Installation....13887
Third Seat Belt and Associated Parts (Long Wheel Base)....13888
Removal....13888
Inspection....13889
Installation....13889
Front Seat Buckle Assembly....13890
Removal....13890
Installation....13890
Front Seat Buckle Assembly (W/Pretensioner)....13890
Removal....13890
Installation....13890
Rear Center Seat Belt Buckle Assembly....13891
Rear Center Seat Belt Buckle Assembly and Associated Parts....13891
Removal....13891
Installation....13891
Third Seat Belt Buckle and Lock Assembly....13892
Third Seat Belt Buckle and Lock Assembly and Associated Parts....13892
Removal....13892
Installation....13892
Rear Seat Lock Assembly....13893
Removal....13893
Installation....13893
Rear Seat Lock Assembly (Bench Type)....13893
Removal....13893
Installation....13893
Rear Seat Strikers....13894
Removal....13894
Installation....13894
Third Seat Striker....13894
Removal....13894
Installation....13894
Main Data and Specifications....13895
9J SUPPLEMENTAL RESTRAINT SYSTEM....13896
Service Precaution....13896
General Description....13897
SRS Component And Wiring Location View....13899
Component Description....13899
Definitions....13902
Diagnosis....13903
SRS Connector Body Face Views....13904
Repairs And Inspections Required After An Accident....13904
On–Vehicle Service....13905
Air Bag Assembly Handling / Shipping / Scrapping....13906
Pretensioner Seat Belt Handling / Shipping / Scrapping.....13906
Special Tools....13921
Service Precautions for SRS Component Service....13925
SRS Connectors....13926
Sensing And Diagnostic Module (SDM)....13928
Service Precautions....13928
Removal....13928
Installation....13928
Driver Air Bag Assembly....13930
Service Precautions....13930
Removal....13930
Installation....13931
Steering Wheel....13932
Service Precautions....13932
Removal....13932
Installation....13933
SRS Coil Assembly....13934
Service Precautions....13934
Removal....13934
Installation....13936
SRS Coil Replacement Procedure....13937
Removal....13937
How to Disconnect the horn terminal....13938
How to Connect Horn Terminal....13938
Installation....13939
Steering Column....13939
Service Precautions....13939
Removal....13939
Installation....13941
Passenger Air Bag Assembly....13943
Service Precautions....13943
Removal....13943
Installation....13943
Pretensioner Seat Belt (If so equipped)....13944
Service Precaution....13944
Parts Location....13944
Removal....13944
Installation....13944
Main Data and Specifications....13945
9J1 RESTRAINT CONTROL SYSTEM....13946
Service Precaution....13946
Diagnostic Information....13947
System Schematic....13949
SRS Diagnostic System Check....13949
Chart A SDM Integrity Check....13951
Chart B “AIR BAG” Warning Lamp Comes “ON” Steady....13953
Chart C “AIR BAG” Warning Lamp Does Not Come “ON” Steady....13955
DTC 15 Passenger Deployment Loop Resistance High....13958
DTC 16 Passenger Deployment loop Resistance Low....13960
DTC 17 Passenger Deployment Loop Open....13962
DTC 18 Passenger Deployment Loop Short To Ground....13964
DTC 19 Passenger Deployment Loop Short To B+....13966
DTC 21 Driver Deployment Loop Resistance High....13968
DTC 22 Driver Deployment Loop Resistance Low....13971
DTC 24 Driver Deployment Loop Short To Ground....13974
DTC 25 Driver Deployment Loop Short To B+....13976
DTC 26 Driver Deployment Loop Open....13978
DTC 51 Air Bag Deployment Event Commanded....13980
DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy Reserves Out Of Range....13982
DTC 61 Warning Lamp Circuit Failure....13984
DTC 71 Internal SDM Fault....13986
DTC 29 Passenger Pretensioner Loop Short To Ground....13988
DTC 31 Passenger Pretensioner Loop Resistance High....13990
DTC 32 Passenger Pretensioner loop Resistance Low....13992
DTC 33 Passenger Pretensioner Loop Short To Voltage....13994
DTC 34 Passenger Pretensioner Loop Open....13996
DTC 41 Driver Pretensioner Loop Resistance High....13998
DTC 42 Driver Pretensioner Loop Resistance Low....14000
DTC 44 Driver Pretensioner Loop Open....14002
DTC 45 Driver Pretensioner Loop Short To Ground....14004
DTC 46 Driver Pretensioner Loop Short To Voltage....14006
DTC 52 Pretensioner Deployment Event Commanded....14008
Sec.10 CONTROL SYSTEM....14010
10A CRUISE CONTROL SYSTEM....14010
Service Precaution....14010
General Description....14010
Diagnosis....14011
Brake Switch....14011
Removal....14011
Installation....14011
Adjustment....14012
Clutch Switch....14012
Removal and Installation....14012
Adjustment....14012
Starter Switch....14013
Removal....14013
Installation....14013
Cruise Control Main Switch....14014
Removal....14014
Installation....14014
Cruise Control Switch (Combination Switch)....14014
Removal and Installation....14014
Cruise Control Unit....14015
Removal....14015
Installation....14015
Cruise Actuator....14016
Actuator Cable Diagram (LHD)....14016
Actuator Cable Diagram (RHD)....14016
Removal....14017
Installation....14017
Mode Switch....14017
Removal and Installation....14017
alternate....14018
Isuzu Trooper All Models Service Repair Manual
